The U.S. Department of Energy’s (DOE) Industrial Technologies Office (ITO) announced the selection of 56 projects to enhance the competitiveness of the U.S. industrial sector and lower the operational costs of producing essential commodities.
Award and cost share amounts are subject to change pending negotiations.
The selected projects will address critical industrial challenges in the following areas:
Project Title: Production of Polyesters via the Furan Pathway
Project Lead: KSE, Inc.
Project Partners: University of Massachusetts Amherst
City/State: Sunderland, MA
Federal Funding: $2,508,000
Project Number: EE0011808
Project Description: KSE, Inc. and partners will develop a new process to develop bio-based polyesters, based on the demonstration of a cost-effective production route for 2,5-furandicarboxylic acid (FDCA). FDCA is used to produce PEF (polyethylene furanoate), a plastic used to make products like bottles and/or food packaging. PEF is a higher performing polymer compared to common plastics like PET (polyethylene terephthalate). When compared to commercial FDCA production, the technology that will be developed in this project has the potential to simplify unit processes and reduce capital and operational costs while improving operational margins.
Project Title: Olefin Purification Membranes with High Separation Performance and Stability
Project Lead: ChemFinity Technologies, Inc.
Project Partners: Membrane Technology and Research, Inc.
City/State: Brooklyn, NY
Federal Funding: $3,000,000
Project Number: EE0011809
Project Description: ChemFinity Technologies, Inc. and its partner aim to develop a durable membrane technology to separate paraffins (saturated hydrocarbons) from olefins (unsaturated hydrocarbons), creating a more cost-effective process to isolate ethylene and propylene, two of the most used petrochemicals in the supply chain of products like plastic bottles and packaging for household cleaners. The mixed matrix membranes, which combine more conventional polymers with unique metal organic framework materials, offer improved separation compared to traditional processes like cryogenic distillation or other membrane technologies. This technology has the potential to improve energy productivity by 90%, reduce operating costs by 35%, and reduce required capital expenses by 50% relative to traditional thermal separation.
Project Title: Nitrogen Fixation for Production of Nitrogenous and Phosphatic Fertilizers
Project Lead: Nitricity, Inc.
Project Partners: N/A
City/State: Fremont, CA
Federal Funding: $5,000,000
Project Number: EE0011807
Project Description: Nitricity will optimize and scale a large-scale plasma reactor to convert air, water, and electricity into nitrate-based fertilizer, an alternative to Haber Bosch (HB) production of ammonia. Developing pathways to directly produce fertilizers, without first making ammonia, can provide a secure, alternative pathway for chemical supply chains. The project combines advanced computational modeling with pilot-scale demonstration. The technology allows for the low-cost, localized production of fertilizers, reducing imports and nitrous oxide pollution, while strengthening American competitiveness.
Project Title: Development of Biological Textile Recycling Process for Cost-Competitive Polyester Production
Project Lead: Protein Evolution, Inc.
Project Partners: Xytel, National Laboratory of the Rockies (NLR)
City/State: New Haven, CT
Federal Funding: $3,000,000
Project Number: EE0011810
Project Description: Protein Evolution and project partners will convert waste derived from PET (polyethylene terephthalate) textiles into high-quality polyester starting material. The project will optimize and scale up a process using enzymes to break down PET plastics and create the building blocks for new polyester. This process will operate with low costs to enable a new, competitive raw material supply.
Project Title: Thermocatalytic Dimethyl Ether Synthesis from Waste
Project Lead: Washington University in St. Louis.
Project Partners: BASF Corporation, National Laboratory of the Rockies (NLR)
City/State: St. Louis, MO
Federal Funding: $2,100,000
Project Number: EE0011812
Project Description: Washington University and partners will produce dimethyl ether (DME), a gas with multiple applications in chemical and fuel production. Combining multiple technologies such as advanced catalysts to improve the operation of chemical reactors and selective heating strategies for precision control, the process for DME production designed in this project can significantly improve energy productivity, reaction performance, and catalyst lifetime. This project aims to create a 2 kg/day prototype of a scalable system that can perform with multiple feedstock sources and reduce production costs by 33% compared to currently dominant DME technology systems.
Project Title: Enabling a Reliable Pathway for the Conversion of Municipal Solid Waste to Cost-Competitive Methanol
Project Lead: GTI Energy
Project Partners: Dow Chemical Company
City/State: Des Plaines, IL
Federal Funding: $3,000,000
Project Number: EE0011813
Project Description: GTI Energy and Dow Chemical are developing a system to convert difficult-to-process municipal solid waste (MSW) into valuable chemical and fuel intermediates. This project will design, build, and test a novel twin-pyrolysis-auger system that enhances heat transfer compared to previous systems. This technology overcomes barriers in equipment fouling (eliminating unwanted material buildup) and in high-material costs encountered by previous systems. The result is a 50% reduction in capital costs and a potential 60% improvement in energy productivity during the production of methanol.
Project Title: Enabling Production and Utilization of Dicarboxylic Acids from Polyolefins
Project Lead: Sandia National Laboratories
Project Partners: Meredian Bioplastics dba Danimer Scientific, Algenesis Corporation, Sulzer Chemtech USA, Inc., Lawrence Berkeley National Laboratory
City/State: Livermore, CA
Federal Funding: $2,371,340
Project Number: LAB
Project Description: Sandia National Laboratory (SNL) and partners are developing a technology to turn discarded polyolefin waste into value-added dicarboxylic acids (DCA) to produce polyurethane and other commonly used commercial polymer products. This project will optimize chemical deconstruction, separation, and conversion processes, creating a clear pathway for commercialization through direct industry collaboration for each process. Compared to other DCA production methods, this technology can create a 30% increase in energy productivity and reduce costs by 15-60%. Demonstration of an economical, alternative domestic supply chain for DCA has potential to improve competitiveness in a polymers market valued at $224 million.
Project Title: Catalyst Regeneration and Induction to Advance the Chemical Value Chain
Project Lead: Idaho National Laboratory
Project Partners: Clariant Corporation, Alkegen
City/State: Idaho Falls, ID
Federal Funding: $3,000,000
Project Number: LAB
Project Description: Idaho National Laboratory (INL) and industrial partners plan to develop a novel catalyst and chemical manufacturing process to enable efficient catalyst regeneration and increase propylene production for existing reactor systems. This process has wide-ranging applications in reaction and regeneration sciences, creating commercialization opportunities. By combining this novel catalyst with targeted induction heating process, INL will not only increase catalyst lifetimes, but also increase product yields, reduce nitrous oxide, and reduce manufacturing energy costs. Aiding this design process will be the development of new experimental and modeling capabilities built on Dynamic Catalyst Science to address key knowledge gaps in catalyst and process development for radio frequency (RF) induction catalysts.Project Title: Energy Efficient Comminution and Advanced Separation Technology for the Production of Direct Reduction (DR) Grade High-Quality Iron Ores
Project Lead: University of Nevada: Reno
Project Partners: University of Utah
City/State: Reno, NV
Federal Funding: $2,092,583
Project Number: EE0011821
Project Description: The University of Nevada: Reno will develop a novel beneficiation process flowsheet (a process used to reduce gangue, or the non-valuable rock surrounding valuable ore, from ore) to transform domestic hematite into direct-reduction-quality iron ore, or ore with at least 67% iron. Techniques like x-ray transmission sorting, high pressure grinding rolls, ball mining, and bacterial flocculation (clumping) will be utilized to transform the hematite. This new process will produce a concentrate of 70% iron with less than 2% gangue. Increasing the domestic availability of direct-reduction grade ore will expand ironmaking capacity in the U.S., help domestic ore producers compete on the global market, and reduce operating costs.
Project Title: MagneLite: A Novel, Low-Cost Process for Magnetite Production
Project Lead: Research Triangle Institute
Project Partners: Gunnadoo Consulting, LLC, Thar Energy, LLC
City/State: Durham, NC
Federal Funding: $2,500,000
Project Number: EE0011816
Project Description: Research Triangle Institute will develop a process that converts olivine, a common mineral that has iron content too low to be classified as an ore, into multiple value streams including the high-grade iron ore magnetite, hydrogen, magnesium carbonate for soil remediation, and silica for concrete aggregate. This process has the ability to create entirely new domestic sources of the high-grade ore necessary for state-of-the-art direct reduced ironmaking.
Project Title: Molten Iron Reduction and Refining of Ores with a Plasma-Interface Anode
Project Lead: Lunar Resources, Inc.
Project Partners: Fond du Lac Band of Lake Superior Chippewa Tribal Government, Texas A&M University, Icon Technology, Siemens USA
City/State: Houston, TX
Federal Funding: $2,988,838
Project Number: EE0011817
Project Description: Lunar Resources, Inc. will advance the technical maturity of molten oxide electrolysis, an alternative ironmaking process that is able to use less expensive and lower-grade ore than is required for conventional ironmaking. Lunar’s technology will protect anodes from degradation when exposed to high temperatures and harsh chemical conditions during the ore melting process. By using high-temperature-resistant materials and a plasma interface to avoid direct contact, this project aims to demonstrate a stable anode without the need to use expensive platinum-group metals. The project has the potential to reduce the cost of steelmaking by about 20%.
Project Title: Circular and Intensified Recovery of Iron Oxide from Abundant Oxidized Resources and Tailings for Sustainable Direct Reduced Iron Technologies
Project Lead: Cornell University
Project Partners: NRRI University of Minnesota, Duluth, National Lab of the Rockies, Nucor
City/State: Ithaca, NY
Federal Funding: $3,000,000
Project Number: EE0011818
Project Description: Cornell University will develop a process to recover valuable, high-grade iron oxide from otherwise discarded steel waste. Using an innovative electrochemical process, the technology will aim to capture the high-grade iron oxide (>68 wt.% Fe) from low-grade mine tailings (waste) and steelmaking furnace slags, or non-metallic waste. The process has high commercialization potential, signaled by partnership with Nucor and U.S. Steel, two of the largest steel producers in the country.
Project Title: Iron Ore Reduction Process Through Sodium Looping
Project Lead: Helios Project Ltd.
Project Partners: NETL, Nucor Corp
City/State: New Freedom, PA
Federal Funding: $3,000,000
Project Number: EE0011819
Project Description: Helios Project Ltd. will develop an ironmaking process, based on using liquid sodium metal, that operates at 500°C, a significantly lower temperature than traditional processes. The new technology will still yield briquettes similar to those produced by direct-reduced ironmaking; however, by reducing the operating temperature, it has the opportunity to reduce capital and operating expenses. The process has high commercialization potential, signaled by partnership with Creative Engineers and Hatch, a major steel equipment engineering company and a major U.S. steel producer.
Project Title: Reduction of Iron Ore Fines and Concentrates Using Non-Thermal Microwave Plasma
Project Lead: Starfire Industries, LLC
Project Partners: Vale S.A., University of Illinois at Urbana-Champaign
City/State: Champaign, IL
Federal Funding: $1,000,000
Project Number: EE0011822
Project Description: Starfire Industries LLC will develop an ironmaking process that uses a non-thermal plasma that can operate at much lower temperatures—approximately 400°C—than traditional processes. The new technology will create briquettes similar to those produced by direct-reduced ironmaking, but by reducing the operating temperature, has the opportunity to reduce capital and operating expenses. The process has high commercialization potential, signaled by partnership with Vale Ventures, a large international mining company.
Project Title: Electrochemical Hydrometallurgy for Flexible Ironmaking
Project Lead: Johns Hopkins University
Project Partners: EDAC Labs, Inc., Argonne National Laboratory
City/State: Baltimore, MD
Federal Funding: $2,138,281
Project Number: EE0011823
Project Description: Johns Hopkins University will produce high-purity iron from low-cost low-grade ores. The novel electrochemical method being developed in this project will separate the iron from the silica, calcium, and magnesium present in the low-grade ore. This process can flexibly accommodate a variety of ores; the team will focus on the most cost-effective ore with the highest potential to process successfully. The calcium and magnesium extracted can also be converted into valuable carbonates, increasing the potential revenue.
Project Title: Evaluating Performance of Electrolytic Iron for Steelmaking in an Electric Arc Furnace
Project Lead: Carnegie Mellon University
Project Partners: ElectraSteel, Inc.
City/State: Pittsburgh, PA
Federal Funding: $1,000,000
Project Number: EE0011824
Project Description: Carnegie Mellon University will develop technology to improve the processability of electrolytically produced pure iron, which is harder to melt than pig iron, in electric arc furnaces. This will help accelerate the technical maturity of electrolytic iron-making, a novel promising process with the potential for producing higher-quality steels more cost-effectively than conventional processes. Through process modelling, laboratory oxidation tests, and melting tests, the team will assess the productivity, quality, and efficiency impact of introducing this new iron product into existing electric arc furnace steelmaking, where it is needed to mitigate the impacts of copper contamination in steel scrap.
Project Title: Induction Smelting of DRI-Processed Low Grade Ores for Steelmaking
Project Lead: University of Minnesota: Duluth
Project Partners: Metcovery II, LLC, National Laboratory of the Rockies
City/State: Minneapolis, MN
Federal Funding: $2,997,738
Project Number: EE0011825
Project Description: The University of Minnesota: Duluth will develop technology to produce pig iron from low-cost low-grade ores. Adding a smelting step to remove impurities from the low-grade ores has the potential to create new cost-effective pathways for state-of-the-art direct reduced ironmaking, which typically requires expensive high-grade ores. The new process allows for smelting to occur continuously instead of in batches, increasing productivity.
Project Title: Production of Improved DRI Feed from Diverse Iron Ore Sources by Reductive Bioleaching
Project Lead: Michigan Technological University
City/State: Hougton, MI
Federal Funding: $1,035,309
Project Number: EE0011826
Project Description: Michigan Technological University will develop technology to convert low-cost, low-grade iron ore waste into valuable iron-using bioleaching, a process that uses microorganisms to concentrate and purify iron from dilute sources. The team will engineer microorganisms in constructed wetlands under controlled conditions. This project will work to enhance the natural ability of the microorganisms to leach iron from the low-grade ore, creating a valuable extraction loop for the creation of usable iron for ironmaking.
Project Title: Selective-Carburization Based Separation of Copper from Shredded Scrap
Project Lead: National Laboratory of the Rockies
Project Partners: Nucor Corporation, Carnegie Mellon University
City/State: Golden, CO
Federal Funding: $706,281
Project Number: LAB
Project Description: The National Laboratory of the Rockies will develop technology to remove copper in steel feedstocks during the heating processes involved in steel production, generating high-value steel. Using a new technology, the lab will electrochemically add carbon to the surface of the scrap, then preheat it to selectively melt out the copper. This innovation is important because no existing process can currently remove copper from solution in steel once it is melted, and the copper content limits the quality of steel products. If successful, this project will reduce the cost of steelmaking by reducing the need for more expensive direct reduced iron in electric arc furnaces.
Project Title: Ironmaking Technique through Electrochemical Re-mining of Red Mud in Alkaline Solutions
Project Lead: Pacific Northwest National Laboratory
Project Partners: Polykala Technologies LLC
City/State: Richland, WA
Federal Funding: $1,000,000
Project Number: LAB
Project Description: Pacific Northwest National Laboratory will develop an electrochemical process that can extract inexpensive iron for steelmaking from red mud, an abundant and readily available waste product of alumina production. In addition to the iron that can be isolated from this process, red mud also contains critical minerals such as rare earth elements, titanium, gallium, and scandium that can be concentrated and extracted for uses like aerospace components, medical implants, computer chips, and more. By de-risking this technology for iron production, this project also has the potential to create opportunities for additional revenue streams for steel manufacturers.Project Title: Reduced Cost Dairy Protein Production Using Precision Fermentation and Dairy Waste Valorization
Project Lead: Ginkgo Bioworks
Project Partners: Aleut Community St. Paul Island; University of Illinois at Urbana-Champaign, Center for Indigenous Science
City/State: Boston, MA
Federal Funding: $2,421,994
Project Number: EE0011827
Project Description: Ginkgo Bioworks will develop a new and more efficient process for producing human lactoferrin (hLF), a vital protein for immune health and infant development. By developing an improved yeast strain streamlining the fermentation process, this new production system will significantly increase output, reduce costs, and shorten production times of hLF. This project will strengthen domestic supply chains for infant nutrition and enhance competitiveness in the global industry.
Project Title: Advanced Antimicrobial Fiber-Based Packaging for the Produce Supply Chain
Project Lead: Michigan State University
Project Partners: Auburn University, Virginia State University, University of Florida, Clemson University, WestRock, Bioelements
City/State: East Lansing, MI
Federal Funding: $1,000,000
Project Number: EE0011828
Project Description: Michigan State University will develop a fiber-based packaging solution to replace single-use plastic clamshells. This innovative packaging will extend the shelf life of fresh produce, reduce operational cost, and decrease overall resource use. These advancements will enhance food product durability, reduce waste, and strengthen domestic supply chains.
Project Title: Improving Commercial Food Service Cooking Performance to Strengthen Food Quality, Operational Efficiency and Productivity
Project Lead: GTI Energy
City/State: Des Plaines, IL
Federal Funding: $1,000,000
Project Number: EE0011830
Project Description: GTI Energy will develop advanced gas-fired cooking equipment, optimized to perform with natural gas and fuel blends. Utilizing 3D-printed burner technology, the project will advance commercial kitchen cooking using alternative fuels for gas inputs. This technology will reduce operational costs for commercial foodservice providers, such as restaurants and kitchens.
Project Title: Next-Generation Food Packaging
Project Lead: University of Tennessee: Knoxville
Project Partners: Plant Switch, Georgia Institute of Technology, Oak Ridge National Laboratory, State University of New York College of Environmental Science and Forestry
City/State: Knoxville, TN
Federal Funding: $1,000,000
Project Number: EE0011831
Project Description: University of Tennessee: Knoxville will develop a bio-based packaging film for food and beverage products. The project team will use near-white lignin, a popular plant-derived polymer, as a direct replacement for traditional polymers found in food packaging such as overwrap for frozen meals. The new film has the potential to provide higher strength, flexibility, and durability than traditional polymers, while improving processing and end of life handling. The project is expected to significantly reduce overall costs.
Project Title: Advanced Biopolymer Films for Food Packaging
Project Lead: Mango Materials
Project Partners: Earthfirst Films, Amy's Kitchen
City/State: Oakland, CA
Federal Funding: $1,000,000
Project Number: EE0011832
Project Description: This project will develop a high-performance food packaging film made from bio-derived sources, that has the potential to replace conventional film used in frozen meal overwraps. The material is anticipated to be able to be engineered to deliver comparable strength, flexibility, and durability while improving manufacturing productivity and cost, relative to conventional films.
Project Title: Efficient Production of a High-Protein Food Product
Project Lead: Tender Food, Inc.
City/State: Somerville, CA
Federal Funding: $1,000,000
Project Number: EE0011833
Project Description: Tender Food, Inc. will scale up the production of alternative, high-quality proteins, and validate production methods and cost-effectiveness in commercially relevant environments. Using a patented spinning method to produce fibers from multiple combinations of protein powders, the process accommodates a wider range of protein suppliers, improving supply chain security. Additionally, the new process reduces energy costs compared to conventional methods and increases throughput.
Project Title: Advanced Processing Platform for High Protein Foods
Project Lead: Michigan State University
City/State: East Lansing, MI
Federal Funding: $1,835,288
Project Number: EE0011834
Project Description: Michigan State University will develop a novel protein production process to extract high-quality, high-solubility protein from a variety of crop sources. This technology will significantly increase protein recovery yield, creating a cost-effective and commercially viable alternative to conventional plant protein production methods.
Project Title: Intelligent Solid-State Electromagnetic Microwave Technology to Revolutionize Commercial Kitchens in Foodservice
Project Lead: University of Tennessee: Knoxville
Project Partners: SAIREM Corporation
City/State: Knoxville, TN
Federal Funding: $999,987
Project Number: EE0011835
Project Description: The University of Tennessee: Knoxville will develop advanced, smart microwave cooking systems capable of baking, grilling, frying, and steaming in commercial kitchens. Using machine-learning for precise frequency control, the systems will closely emulate traditional cooking processes with high precision at scale for different kitchen sizes and functions. The technology will cut energy waste in half across cooking methods compared to conventional cooking methods, with the potential to significantly reduce operating costs.
Project Title: Advancing Commercial Food Service Equipment Through Dual-Power Infrared Heating
Project Lead: Oak Ridge National Laboratory
Project Partners: Solaronics, Inc., Trimac Industrial Systems, New Buildings Institute
City/State: Oakridge, TN
Federal Funding: $1,000,000
Project Number: LAB
Project Description: Oak Ridge National Laboratory will develop and demonstrate a dual-power infrared heating technology for commercial kitchens. This technology utilizes a patent-pending metal foam combustion system to create precise heating control with high thermal output, making it comparable to a wide range of commercial equipment such as vat fryers, baking ovens, and clamshell grills, while using significantly less energy. The hybrid technology ultimately offers commercial kitchens a more efficient, cost-effective solution that strengthens operational performance and competitiveness.Project Title: Incorporating Tribology Principle into Asphalt Mix Design for Improved Asphalt Pavement
Project Lead: University of Wisconsin-Madison
Project Partners: California State University, Michigan Technological University, Honeywell International Inc., Pike Industries, Asphalt Materials, Inc.
City/State: Madison, WI
Federal Funding: $800,000
Project Number: EE0011841
Project Description: The University of Wisconsin-Madison and partners are applying tribology principles to asphalt pavement design, production, and placement, resulting in a more durable asphalt pavement. Through the application of tribology principles, asphalt mixtures will be optimized for improved lubrication and workability, leading to lower production and placement temperatures, better compaction, and reduced asphalt binder content. The expected goal is to extend pavement longevity by at least 10% while conserving materials and improving mechanical performance.
Project Title: Advanced Cold Recycling Pavement System with Enhanced Curing, Improved Mechanical Properties, and Asphalt Binder Reactivation
Project Lead: Purdue University
Project Partners: N/A
City/State: Lafayette, IN
Federal Funding: $800,000
Project Number: EE0011837
Project Description: Purdue University will combine carbon-rich filler, known as carbon black (CB), with 100% recycled asphalt pavement (RAP) to develop a cold mix asphalt (CMA) solution. Carbon black enhances electrical conductivity, enabling self-heating capabilities which reactivate the binder found in RAP, reducing the need for additional asphalt binder. This innovative approach aims to improve CMA properties such as curing time, compaction, and mechanical strength, offering a performance and cost-optimized alternative to traditional hot mix asphalt and creating a durable, cost-efficient pavement system.
Project Title: Low-Cost Advanced Cement Material From Abundant Raw Materials
Project Lead: Solid Carbon, Inc.
Project Partners: National Laboratory of the Rockies, Oregon State University, University of Kentucky, Wilsonville Concrete product, Amrize
City/State: McMinnville, OR
Federal Funding: $3,000,000
Project Number: EE0011840
Project Description: Solid Carbon, Inc. and partners will develop and scale next-generation concretes utilizing novel materials. The project will incorporate belite-rich calcium sulfoaluminate (BCSA) and super sulfated slag (SSS) cements with alternative supplementary materials from underwater waste streams, specifically those found in high ash-fraction forest waste biochar from tree thinning and wastewater incinerator ash. This process will expand the supply chain for cement production, increasing domestic security and competitiveness.
Project Title: Development of Concretes Containing High-Volume Calcined and Mechanochemically Activated Clays and Carbonated Recycled Concrete Aggregates
Project Lead: University of Miami
Project Partners: Illinois Institute of Technology, Ozinga Bros., Inc.
City/State: Coral Gables, FL
Federal Funding: $2,999,966
Project Number: EE0011842
Project Description: The University of Miami will produce next-generation concrete mixtures to replace 60-75% of clinker, a primary binder in concrete, by advancing the use of low-to mid-kaolinitic content clays (LMKCs), portland limestone cement, and engineered recycled concrete aggregate. The technology enhances LMKC reactivity through calcination or mechanochemical activation (induction of chemical reactions via mechanical energy), to enable high clinker replacement within ASTM (American Society for Testing and Materials) standards. This approach promotes the use of abundant, underutilized materials, improves infrastructure, and reduces operational costs.
Project Title: Asphalt from Waste Materials and Bio-Based Additives
Project Lead: National Laboratory of the Rockies
Project Partners: Driven Plastics, Metropolitan State University
City/State: Golden, CO
Federal Funding: $993,320
Project Number: LAB
Project Description: National Laboratory of the Rockies will develop next-generation asphalt solutions by integrating waste materials into asphalt mixtures. The technology incorporates hard-to-recycle post-consumer polyethylene (PE) film waste from items like grocery bags and shrink wrap and recycled asphalt pavement (RAP) with warm-mix additives and bio-based rejuvenators (petroleum alternatives). This mix is expected to reduce production temperatures by at least 40 degrees, reducing operational costs, strengthening supply chains, and creating a market for underutilized domestic resources.
Project Title: Limestone/Activated Clay/Calcium Sulfate Blends for Concrete
Project Lead: Oak Ridge National Laboratory
Project Partners: University of Texas Austin, Georgia Institute of Technology, ACEEE, Imerys, Carbon Upcycling, St. Mary Cement, Tindal Corporation, Irving Materials Inc., Precast/prestressed Concrete Institute, Tennessee Concrete Association
City/State: Oak Ridge, TN
Federal Funding: $2,893,000
Project Number: LAB
Project Description: Oak Ridge National Laboratory will develop a next generation binder leveraging readily available domestic materials. The project will develop a physically and compositionally optimized limestone, activated clay, and calcium sulfate (LACCS) blend to partially replace portland cement without significant impact on performance or cost. This innovation will demonstrate the technical and economic feasibility of clay activation by mechanochemical processes like grinding or milling, that do not require heat for activation. This project will enhance the domestic cement supply and strengthen U.S. supply chains.
Project Title: Low-Cost Asphalt Pavements Using Lignin
Project Lead: Lawrence Berkeley National Laboratory
Project Partners: Sandia National Laboratory, North Carolina State University, Murray University, Erg Bio, Inc.
City/State: Berkeley, CA
Federal Funding: $750,000
Project Number: LAB
Project Description: Lawrence Berkeley National Laboratory and partners will develop a next-generation asphalt pavement mix utilizing lignin—an organic polymer found in plant cell walls—to strengthen the binder supply chain. This new solution will lower processing temperatures, enhance performance, and mitigate volatile organic compound (VOC) emissions while remaining cost-competitive. The natural adhesive behavior of lignin is expected to improve adhesivity, workability, and enhance durability of the asphalt mixture, extending the lifespan of roads. Through demonstrating compliance with existing American Association of State Highway and Transportation Officials specifications, this project will expedite market adoption and commercialization of the next-generation asphalt pavement mix.
Project Title: Manufacturing of Cement and Concrete Enabled by Electrochemical Technologies
Project Lead: University of California, Irvine
Project Partners: De Nora Tech LLC, Oak Ridge National Laboratory
City/State: Irvine, FL
Federal Funding: $3,000,000
Project Number: EE0011838
Project Description: The University of California, Irvine and partners will create a new process to produce cement without the use of traditional kiln combustion methods. Using an electrochemical process, the technology will create calcium hydroxide in an electrolyzer, instead of a kiln, which operates at significantly lower temperatures, saving on operational costs. The next-generation cement will be compliant with existing ASTM (American Society for Testing and Materials) standards.
Project Title: Recycling End of Life Glass (RE-Glass)
Project Lead: Carbon Rivers, Inc.
Project Partners: TPI Composites, Inc., Johns Manville
City/State: Knoxville, TN
Federal Funding: $868,622
Project Number: EE0011839
Project Description: Carbon Rivers, Inc. and partners will develop and demonstrate Isochoric Thermal Hydrolysis (ITH), a novel process for repurposing post-consumer and post-industrial fiberglass waste containing the difficult-to-recycle Urea-formaldehyde. This low-cost process prepares fiberglass for remelting or direct reuse at lower processing temperature than traditional methods, saving operational costs.Project Title: AI Controlled Vapor-Compression-Ejector Wood Dryer with an Oscillating Heat Pipe Energy Recovery Dehumidifier
Project Lead: University of Missouri: Columbia
Project Partners: Micro Nano Technologies, Forest Concepts, LLC, National Laboratory of the Rockies, Michigan Technological University, Texas A&M University
City/State: Columbia, MO
Federal Funding: $2,651,506
Project Number: EE0011847
Project Description: The University of Missouri: Columbia and partners will develop and demonstrate an advanced process heat system for drying wood and recovering heat used in the process. A novel energy recovery unit will recover both sensible heat (heat transferred due to a temperature difference) and latent heat (heat transferred due to a phase change) from the drying chamber. The modular design will enable the system to be integrated with existing kilns, increasing industrial adoption. The team will also design an AI control system based on wood drying/quality data. This technology will reduce operating costs by at least 50% compared to similar commercial systems.
Project Title: Enhanced Recycled Paper Fiber Recovery Using Anaerobic Digestion
Project Lead: Research Triangle Institute
Project Partners: North Carolina State University
City/State: Research Triangle Park, NC
Federal Funding: $3,000,000
Project Number: EE0011845
Project Description: Research Triangle Institute and partners will develop an innovative fermentation process to increase the yield of recovered cellulose fibers from old corrugated containers (OCC) and co-produce biogas as a byproduct. The project will use anaerobic digestion (AD) to selectively break down non-cellulosic organic materials like starch and hemicellulose. AD pulping technology reduces feedstock preprocessing, lowers energy demand for fiber recovery, and produces biogas to use as an energy source for drying. The project will demonstrate 100 days of continuous operation with at least 100 kg of OCC, >70% cellulose fiber recovery, and a minimum of 120 m3 of biogas/ton of OCC, without significant loss of fiber quality compared to incumbent technologies.
Project Title: Alternative Chemical Recovery for Kraft Pulp Mills
Project Lead: University of Maine
Project Partners: WestRock
City/State: Oronon, ME
Federal Funding: $2,165,568
Project Number: EE0011848
Project Description: The University of Maine and partners will investigate the application of Direct Alkali Recovery Systems by separating sulfur recovery from sodium recovery in the kraft process. The proposed scheme will recover three components: 1) sulfur from the acidification of black liquor (the primary biproduct of the kraft pulping process), 2) lignin from deep eutectic solvent extraction (a solvent formed by mixing hydrogen bond donors and hydrogen bond acceptors), and 3) sodium hydroxide from direct causticization of the remaining liquor via inductive heating. By decoupling chemical recovery from energy generation, this process creates a competitive advantage by using flexible power sources while generating additional revenue from the recovered lignin.
Project Title: Novel Membrane Electrolysis Process for Improved Kraft Chemical Recovery
Project Lead: University of Cincinnati
Project Partners: Bettergy Corporation, Giner, Inc., Idaho National Laboratory, Washington State University
City/State: Cincinnati, OH
Federal Funding: $2,999,791
Project Number: EE0011849
Project Description: The University of Cincinnati and partners will develop a novel approach to recover chemicals in the kraft pulping process. The technology utilizes new membranes to create concentrated black liquor, a lignin laden byproduct of pulp production, and membrane electrolysis to separate and recover sodium hydroxide from green liquor, the solution created when recovery boiler residuals are redissolved in water. The proposed work will establish lab-scale equipment and processes to serve as the basis for scale up, as well as technoeconomic analysis to test industrial viability. The proposed technologies have the potential to increase production capacity by 10% compared to traditional processes.
Project Title: Electrified acid hydrotropic pulping for forest and pulping industries
Project Lead: Iowa State University
Project Partners: Oak Ridge National Laboratory, Sappi North America, USDA Forest Product Laboratory
City/State: Ames, IA
Federal Funding: $1,680,000
Project Number: EE0011850
Project Description: Iowa State University and partners will improve the pulping process by developing a novel, electrified hydrotropic acid pulping technology to separate woody biomass into cellulose, hemicellulose, and lignin for commercial applications. This technology will reduce the processing time and number of steps in traditional pulping processes. The project will develop hydrophobic biodegradable packaging materials, or packaging that resists moisture while still breaking down, by utilizing unbleached pulp and producing a value-added lignin stream. If successful this project will reduce processing time for pulping by up to 80% compared to the kraft process and increase the number of products available from pulp mills, increasing revenue.
Project Title: Dewatering Wood and Pulp Products Using Supercritical Carbon Dioxide (scCO2) Through its Cyclical Phase Change Between Supercritical Fluid and Gas
Project Lead: Auburn University
Project Partners: N/A
City/State: Auburn, AL
Federal Funding: $579,469
Project Number: EE0011869
Project Description: Auburn University and partners will develop a novel dewatering process using the phase change of supercritical carbon dioxide. The project will be optimized for softwoods, hardwoods, wood particles and pulp fibers and be evaluated based on end-product applications and energy use. This project could reduce volatile organic compound production by 50-85%, improving air quality compared to traditional kiln drying.
Project Title: Mild Co-solvent Pulping for the Paper and Forest Products Sector
Project Lead: University of California: Riverside
Project Partners: University of Tennessee-Knoxville, State University of New York College of Environmental Science and Forestry, Georgia Institute of Technology, ORNL, The Hurd Co
City/State: Riverside, CA
Federal Funding: $1,450,000
Project Number: EE0011228
Project Description: The University of California: Riverside and partners will develop and demonstrate a strategy to produce dissolving-grade pulp (pulp with high cellulose content) from U.S. hardwood. Dissolving-grade pulp can be spun into fibers to make textiles and materials like rayon and cellophane. Using mild co-solvent pulping reduces operational costs compared to traditional prehydrolysis kraft pulping, which requires an additional step to loosen the cell structure. If successfully developed, the technology will reduce costs by 10-20%, increase throughput, improve lignin recovery for use in multiple applications, reduce hazardous waste, eliminate odorous sulfurous gas, and lower particulate production. These improvements in the production process will create a unique, competitive advantage for American paper and forest product manufacturers.Project Title: Evaluating Novel Integration and Optimization for Chemicals
Project Lead: Lyondell Chemical Company
Project Partners: N/A
City/State: Houston, TX
Federal Funding: $1,500,000
Project Number: EE0011851
Project Description: Lyondell Chemical Company and partners will develop an engineering design that combines multiple technologies across the ethylene production process. The U.S. produces 35 million tons of ethylene per year. Improving the production process can yield a 30% reduction in capital costs. The pre-FEED study at Lyondell Chemical’s La Porte, Texas facility, the second largest train cracker (the machinery that produces the building blocks of ethylene) in North America, will define technology feasibility, economics, and engineering requirements for ethylene technology integration.
Project Title: On-Site Production of Formate Chemicals from Industrial Waste-Gas
Project Lead: OCOchem
Project Partners: Ionada, LambWeston
City/State: Richland, WA
Federal Funding: $1,200,000
Project Number: EE0011854
Project Description: OCOchem and partners will develop a study for value-added chemicals produced from waste gas at small and mid-size industrial facilities. The Preliminary Front-End Engineering Design study will define technology feasibility, economics, and engineering requirements for post-combustion capture and conversion to formic acid at 25% lower costs than incumbent formic acid production. The project advances multiple next-generation technologies, including hollow fiber membranes and electrochemical reactors at industrial scale.Project Title: High Temperature Industrial Heat Enabled by Advanced Heating Element
Project Lead: Rondo Energy, Inc.
Project Partners: National Laboratory of the Rockies
City/State: Alameda, CA
Federal Funding: $2,999,376
Project Number: EE0011606
Project Description: Rondo Energy, Inc. will develop a high temperature (>1300°C) thermal energy storage system for use in industrial processes. The project will identify and integrate an advanced heating element that will increase storage capacity (>25%) and increase heating rates (>30%) to optimize energy usage while charging. This new technology will provide facility operators with more flexibility and options to optimize processes and lower energy costs. The team will complete a subsystem scale demonstration (1MWh level) of the advanced heating element integrated with Rondo’s existing storage material under relevant industrial conditions.
Project Title: High Efficiency, Oil-Free Mechanical Vapor Compression System
Project Lead: Blue Mountain Energy
Project Partners: Danfoss; Oak Ridge National Laboratory; Honeywell; University of Virginia; University of New Hampshire
City/State: North Las Vegas, NV
Federal Funding: $3,000,000
Project Number: EE0011607
Project Description: Blue Mountain Energy and partners will develop and evaluate a cost-effective, closed-cycle mechanical vapor compression (MVC) system—a system that utilizes a sealed loop of refrigerant driven by a mechanical compressor for cooling or heating applications. The MVC system can reduce operating expenses. The project will make advancements across all subsystems, including the development of a novel centrifugal compressor; elimination of lubricant oils; use of cutting-edge valves, bearings, and control approaches; integration of an interlaced microchannel heat exchanger; and use of an emerging synthetic refrigerant. The technology will provide process heat at up to 160 °C.
Project Title: Additively Manufactured Ceramic Heat Exchanger Advancement for Increased Thermal Efficiency
Project Lead: Pennsylvania State University
Project Partners: Saint-Gobain Ceramics & Plastics, Inc.
City/State: University Park, PA
Federal Funding: $2,491,443
Project Number: EE0011611
Project Description: Pennsylvania State University and partners will develop and demonstrate a novel ceramic heat exchanger to recover heat in direct-fired processes at temperatures over 800°C. In this new technology, Si-SiC—a reaction-bonded ceramic made by permeating porous carbon with molten silicon—will replace metal-based heat exchangers operating at lower temperatures, improving the fabrication process and significantly improving the overall efficiency. By using additive manufacturing (3D printing) the team can custom-shape this heat exchanger to fit directly into existing industrial ovens and kilns across many industries without requiring a full system rebuild. This allows factories to safely and economically capture heat from harsh, corrosive exhaust gases.Project Title: Photocatalytic Disinfection to Eliminate Unwanted Byproducts in Wastewater Treatment
Project Lead: Louisiana State University
Project Partners: South Baton Rouge Wastewater Treatment Plant, Kingdom Technology Services
City/State: Baton Rouge, LA
Federal Funding: $2,237,383
Project Number: EE0011616
Project Description: This project identifies a significant issue in wastewater treatment processes: the interaction of chlorine compounds (widely used for disinfection) with wastewater residuals can create toxic disinfection byproducts. Through this project, Louisiana State University will use an innovative catalyst that replaces chlorine additives—while still meeting disinfection standards—to avoid producing toxic byproducts. This innovative new process will save electricity and costs for wastewater treatment plants and ratepayers.
Project Title: Achieving Efficient Biological Nitrogen Removal through an Electron Balancing Approach
Project Lead: Columbia University
Project Partners: New York City Department of Environmental Protection, DC Water, RESbonds, and City University of New York-City College of New York
City/State: New York, NY
Federal Funding: $2,495,585
Project Number: EE0011617
Project Description: Columbia University and partners will develop and implement control strategies in biological nitrogen removal (BNR) and non-BNR processes, addressing increasingly stringent regulations governing nitrogen removal. The new strategies will reduce the cost of adding supplemental carbon in the nitrogen removal process. The project team will use past results on microbial mechanisms, alternative metabolic pathways which produce different intermediate products, and operating conditions and reactor configurations associated with nitrogen removal at wastewater resource recovery facilities.
Project Title: Autothermal Pyrolysis of Wastewater Solids for Sludge Volume Reductions
Project Lead: Philadelphia Water Department
Project Partners: Iowa State University, The Mott MacDonald Group
City/State: Philadelphia, PA
Federal Funding: $2,497,554
Project Number: EE0011619
Project Description: The Philadelphia Water Department and partners will optimize the performance of autothermal pyrolysis—a thermochemical process that converts wastewater biosolids into biochar and hot exhaust gases. Autothermal pyrolysis internally generates the thermal energy needed to drive pyrolysis, or the heating of materials without oxygen, eliminating the need for external energy sources. This technology can reduce reactor costs, intensify reactions, and increase throughput compared to conventional pyrolysis. Optimized autothermal pyrolysis has the potential to replace land application, landfilling, and incineration of biosolids, thereby dramatically reducing disposal costs.
Project Title: Advancing Nitrogen Removal from Wastewater through Ammonia Ion-Exchange and Electrolysis Technologies
Project Lead: University of Illinois Urbana-Champaign
Project Partners: Stanford University, Urbana Champaign Sanitary District, Current Water Technologies, Inc., U.S. Army Corps of Engineers, Colorado State University, Visage Energy
City/State: Champaign, IL
Federal Funding: $2,495,585
Project Number: EE0011620
Project Descriptions: The University of Illinois Urbana-Champaign and partners will eliminate the need for energy-intensive aeration in ammonia removal processes by bypassing traditional nitrification/denitrification steps. The technology project will have two focus areas: 1) improve catalyst design, further investigating both indirect and direct ammonia oxidation methods, and 2) demonstrating direct electrolysis of ammonia into nitrogen and hydrogen gases. These advancements will be scaled both at bench- and pilot-scale and will reduce chemical costs.