Oak Ridge Today

New director hired at ORNL Carbon Fiber Technology Facility

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Merlin Theodore, new director of Oak Ridge National Laboratory's Carbon Fiber Technology Facility. (Photo by ORNL)

Merlin Theodore, new director of Oak Ridge National Laboratory’s Carbon Fiber Technology Facility. (Photo by ORNL)

 

A new director has been hired at the Carbon Fiber Technology Facility at Oak Ridge National Laboratory.

Merlin Theodore most recently worked in Moses Lake, Washington, where she established a laboratory and promoted organizational excellence at a startup facility, SGL Automotive Carbon Fiber, ORNL said in a story published on its website in March. SGL Automotive Carbon Fiber is one of the largest carbon fiber production facilities in the United States, ORNL said.

While at SGL Automotive Carbon Fiber, Theodore boosted workflow efficiency by 97 percent and achieved 94 percent cost savings by developing new testing methods to determine sizing concentration on fiber surface, ORNL said. She also played an instrumental role in resolving technical issues for automaker BMW.

Theodore was the first in her family of 11 siblings to pursue graduate studies and then take up a career as a technology innovator. Her path eventually led her to ORNL, the lab said.

Before the Carbon Fiber Technology Facility and SGL Automotive Carbon Fiber, Theodore worked for Bayer Pharmaceuticals, Georgia Tech, and Universal Technology Corporation, or UTC, at Wright-Patterson Air Force Base as a research scientist and laboratory manager. [Read more…]

LeMond Composites to make carbon fiber, composite bicycles—invest $125 million, create 242 jobs

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lemond-composites-greg-lemond-2-oct-12-2016-web

Greg LeMond, three-time Tour de France champion, celebrated the opening of LeMond Composites, a new company he co-founded, during a ceremony on Wednesday afternoon, Oct. 12, 2016, at Horizon Center in west Oak Ridge. The company is expected to make composite bicycles and carbon fiber, and invest $125 million and create 242 new jobs. (Photo by John Huotari/Oak Ridge Today)

A new company co-founded by Greg LeMond, a three-time Tour de France champion, will make composite bicycles and carbon fiber for other products in Oak Ridge, and the business, called LeMond Composites, will invest $125 million and create 242 new jobs, officials said during a Wednesday afternoon ceremony.

Among the officials celebrating the opening on Wednesday were LeMond, and Tennessee Economic and Community Development Commissioner Randy Boyd.

Carbon fiber has advantageous properties, but cost has been a barrier to using it, said Connie Jackson, chief executive officer of LeMond Composites. She said the manufacturing process has been changed to reduce production cost.

“We have overcome a significant part of the cost barrier,” Jackson said.

Carbon fiber is light, stiff, and strong, making it the perfect material for advanced composites in a variety of applications. It can be used to improve efficiency, save energy, and build or repair vehicles and planes, wind turbines and containers, and bridges and tunnels. [Read more…]

Opinion: Alexander discusses ETTP demolition, development; Oak Ridge cleanup work

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Lamar Alexander

Lamar Alexander

By Lamar Alexander

This week marked the end of an era. The last of the five uranium enrichment buildings in Oak Ridge has been cleaned up, making land available for new companies and new jobs coming to East Tennessee.

Tennessee should be extremely proud of the men and women who have worked for more than a decade to complete the demolition and cleanup at the East Tennessee Technology Park.

The story of how these buildings first came to be built is by now a familiar one. In 1942, President Franklin D. Roosevelt asked Senator Kenneth McKellar, the Tennessean who chaired the Appropriations Committee, to hide $2 billion for a secret project to win World War II. McKellar replied, “Mr. President, I have just one question: Where in Tennessee do you want me to hide it?”

They hid it in Oak Ridge, on 2,200 acres along the Clinch River, where they quietly built K-25, the largest building in the world, to enrich uranium through gaseous diffusion—a complicated and now mostly obsolete process. [Read more…]

Oak Ridge supports ORNL, LeMond Composites carbon fiber partnership

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Jones LeMond Watson and Creswell Aug 31 2016

Pictured above at a meeting on Wednesday, Aug. 31, 2016, on a new carbon fiber partnership between Oak Ridge-based company LeMond Composites and Oak Ridge National Laboratory are, from left, Steve Jones (Oak Ridge economic development consultant), Greg LeMond (LeMond Composites), Mark Watson (Oak Ridge city manager), and Wade Creswell (president of The Roane Alliance). (Photo by City of Oak Ridge)

 

By City of Oak Ridge

The City of Oak Ridge is proud to support the recent announcement that LeMond Composites, a new company in Oak Ridge offering solutions for high-volume and low-cost carbon fiber, has secured a licensing agreement with Oak Ridge National Laboratory.

The news was made public on August 29 in a release from LeMond Composites. The company, founded earlier this year by three-time Tour de France champion Greg LeMond, focuses on making carbon fiber composites with global applications. The agreement with ORNL will make LeMond Composites the first company to offer these newly developed products to the transportation, renewable energy, and infrastructure markets.

LeMond Composites plans to build their first carbon fiber production line at their recently purchased facility on Palladium Way at Horizon Center in west Oak Ridge. Their first commercially available product is expected to be ready in early 2018.

“I am ecstatic about this unique technological application for carbon fiber in our community,” Oak Ridge Mayor Warren Gooch said. “We look forward to working with LeMond Composites to create jobs and further investment in Oak Ridge.” [Read more…]

LeMond, Tour de France champion, plans production in Oak Ridge, thinks area could be world hub for carbon fiber

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Greg LeMond at the Carbon Fiber Technology Facility

Three-time Tour de France champion Greg LeMond, right, chairman and co-CEO of LeMond Companies, which owns LeMond Composites, tours ORNL’s Carbon Fiber Technology Facility. (Image courtesy of Oak Ridge National Laboratory, U.S. Department of Energy)

 

A new carbon fiber company that includes three-time Tour de France champion Greg LeMond plans to build a carbon fiber production line in west Oak Ridge to make composites for use in transportation, renewable energy, and infrastructure, and LeMond thinks the Knoxville area will become the world hub for carbon fiber.

The new company, LeMond Composites, has signed a licensing agreement with Oak Ridge National Laboratory, and it has purchased the former Theragenics building at Horizon Center, where CVMR, an international company that uses ore concentrates to create pure metal powders, had once planned to locate its headquarters and research and development.

LeMond Composites closed on the property, which includes about 21 acres, on July 21 for $5.4 million. It’s right next to ORNL’s Carbon Fiber Technology Facility, or CFTF, at Horizon Center. Renovations at the former Theragenics building are already under way.

Carbon fiber is light, stiff, and strong, a press release said. That makes it the perfect material for advanced composites in a variety of applications, including transportation, renewable energy, and infrastructure, the release said. It can be used to improve efficiency, save energy, and build or repair vehicles and planes, wind turbines and containers, and bridges and tunnels.

But the biggest obstacle to its widespread use has been its high cost. [Read more…]

Picture: DOE director of economic impact, diversity visits ORNL

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Dot Harris at Oak Ridge National Laboratory

From left, Dot Harris, director of the U.S. Department of Energy’s Office of Economic Impact and Diversity, and Michael Colbert, deputy director of DOE’s Office of Diversity and Inclusion, listen as Research Alliance in Math and Science student Darius Degraffenried presents his research. (Photo by ORNL’s Jason Richards)

The U.S. Department of Energy’s Dot Harris, director of the Office of Economic Impact and Diversity, visited Oak Ridge National Laboratory Thursday and Friday.

Harris spoke at the Research Alliance in Math and Science banquet Thursday evening, and she attended a RAMS poster session that preceded the dinner.

Her agenda also included visits to ORNL’s supercomputing facilities, Spallation Neutron Source, the Carbon Fiber Technology Facility, and the Manufacturing Demonstration Facility, as well as discussions on the lab’s education, outreach, partnerships, and small business programs. [Read more…]

ORNL makes low-cost carbon fiber available to American manufacturers

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Carbon Fiber Technology Facility

Operated by Oak Ridge National Laboratory, the Carbon Fiber Technology Facility is accepting proposals from companies that want to test low-cost carbon fibers manufactured at the pilot scale plant. Pictured here are textile-grade acrylic fibers entering the first of four oxidation ovens, where they gradually turn from white to yellow, auburn, brown, then black. Once fully oxidized, the fiber is ready to run through the higher-temperature furnaces, which convert the oxidized fiber to carbon fiber. (Submitted photo)

Companies interested in testing the latest in low-cost carbon fiber have a new opportunity to partner with the U.S. Department of Energy’s Carbon Fiber Technology Facility.

The CFTF, operated by Oak Ridge National Laboratory as part of the department’s Clean Energy Manufacturing Initiative, opened earlier this year to find ways to reduce carbon fiber production costs and to work with the private sector to stimulate widespread use of the strong, lightweight material.

In its first months of operation, the CFTF used traditional raw materials to assure the new pilot scale manufacturing line would produce a commercial-quality product. With that goal accomplished, the facility now will use less expensive “precursor” materials that can be turned into carbon fiber more cost-effectively. [Read more…]

Guest column: H.M.S. Carbon Fiber

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By Leslie Agron and Pat Fain

Anyone a Gilbert and Sullivan fan?

“When I was a lad I served a term / As office boy to an attorney’s firm. /
I cleaned the windows and I swept the floor, / And I polished up the handle of the big front door.” (HMS Pinafore)

So, how does this go in Oak Ridge? Perhaps: Oak Ridge National Laboratory’s Carbon Fiber Technology Facility will revolutionize the choice of materials used in manufacturing. Major manufactures, such as auto companies, will be falling over themselves soon to locate here, so as to capitalize on the technical information to be transferred from ORNL (possibly, but it might be a few years out yet). They will all want sites in Horizon Center, next to the ORNL demonstration facility, to be closest to the technology (maybe, but remember that Nissan found a Middle Tennessee location adequate for transfer of battery technology they consider vital to their future).

Carbon fiber manufacturing is a high energy-utilizing process. ORNL’s demonstration facility could take most of the 10-megawatt energy capacity at Horizon Center (true, but Horizon Center was designed as a commercial park, not as an industrial park). So we need a large project to bring 20 megawatts of additional electrical capacity into Horizon Center right away to meet this pressing need (hmm…has there been someone knocking at our doors lately that they have not been telling us about? What we seem to need right now is an incremental project to put in a lesser amount of power, especially at peak load times, so that the one or two parcels we might sell soon at Horizon Center will have adequate power available—else they are correct that nothing might sell). [Read more…]

Roane State, ORNL, industries train workers in composites, advanced manufacturing

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John Thornton at Carbon Fiber Technology Facility

John Thornton, left, a graduate of Roane State’s Advanced Materials Training and Education Center and an intern at Oak Ridge National Laboratory’s Carbon Fiber Technology Facility, chats with Roane State President Chris Whaley. (Submitted photos)

John Thornton of Clinton graduated from Roane State Community College’s Advanced Materials Training and Education Center, or AMTEC, a year ago.

Today, he works in one of the most innovative places in the country.

“It’s been an amazing experience,” Thornton said. “It was a once-in-a-lifetime opportunity to be a part of this and hopefully develop a career out of it.”

Thornton is one of 13 AMTEC trainees interning at Oak Ridge National Laboratory’s Carbon Fiber Technology Facility. The $35 million plant is a new advanced manufacturing facility designed to reduce the cost of carbon fiber—a critical material for efficient, lightweight vehicles, next-generation wind turbines, and a wide array of other consumer and industrial products. [Read more…]

Oak Ridge carbon fiber plant could lower cost of strong, lightweight material

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Carbon Fiber Technology Facility

Gary R. Lownsdale of Plasan Carbon Composites, right, talks to Tennessee Gov. Bill Haslam, center, near a Chevrolet Corvette ZR1 hood at the Carbon Fiber Technology Facility on Tuesday as federal, University of Tennessee, and Oak Ridge National Laboratory officials listen.

A unique manufacturing plant in west Oak Ridge that started operating about six weeks ago can make 25 tons of carbon fiber each year. It’s material that could be used for prototype parts in products ranging from cars and airplanes to wind turbine blades and natural gas tanks.

The $35 million Carbon Fiber Technology Facility at Horizon Center Business Park is designed to “scale up” laboratory research on low-cost carbon fiber, make enough material to help industrial partners build prototype carbon-fiber composite parts, and develop a skilled manufacturing workforce.

Carbon fiber is strong and lightweight, but it is also expensive and that has limited its use.

Officials hope to use the 42,000-square-foot Carbon Fiber Technology Facility to change that. They want to make producing carbon fiber as cost-efficient as manufacturing steel or aluminum. [Read more…]

DOE, ORNL to celebrate carbon fiber facility, announce manufacturing initiative

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Officials from the U.S. Department of Energy and Oak Ridge National Laboratory will celebrate a unique carbon fiber facility on Tuesday morning.

DOE will also announce a new U.S. manufacturing initiative during the ceremony at the Oak Ridge National Laboratory’s Carbon Fiber Technology Facility at Horizon Center Business Park in west Oak Ridge. [Read more…]