Towards a circular economy for PET bottle resin using a system dynamics inspired material flow model
Not Available
Ghosh, Tapajyoti (ORCID:0000000205220235)↗
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A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis
This paper examines the impacts of design, operational, and end-of-life (EOL) waste pathways’ parameters on material circularity in silicon solar photovoltaic (PV) modules. Dynamic material flow analysis (DMFA) quantifies time-series material flows through systems’ life cycle stages to identify hotspots of waste generation, estimate resource needs in the future, and guide sustainable material management. We introduce a DMFA framework based on U.S. electricity demand for the period 2000-2100 to assess stocks and flows of bulk PV materials (i.e., solar glass and aluminum frames). We apply the model to a range of scenarios to understand how material demands depend on selected PV-related parameters, different material circularity strategies, and recent module design trends (e.g., bifacials, large-format-high power modules). Our results enable advanced planning for future materials needs and provide insight into potential opportunities to minimize material waste.
circular economy↗
Material flows and GHG emissions from housing stock evolution in US counties, 2020–60
The evolution of housing stocks determines demand for construction materials and energy, and associated emissions of greenhouse gasses (GHGs). The contribution of construction to building life-cycle emissions is growing as buildings become more energy efficient and the energy supply decarbonizes. A housing stock model is developed for counties in the United States using dynamic vacancy rates which endogenously influence stock out- and inflows. Stocks of three house types and 10 construction cohorts are projected for all contiguous US counties for the period 2020–60. Inflows and outflows of construction materials are then estimated along with GHG emissions associated with material production and construction activities in scenarios defined by stock turnover rates, population share by house type, and floor area characteristics of new houses. The results provide new insights into the drivers of construction-related emissions at local and national levels, and identify opportunities for their reduction. Demolition material flows grow in relation to construction material flows over the analysis period. Increasing the stock turnover rate increases future floor area per person, material requirements, and emissions from construction. Scenarios with reduced floor area and more multifamily homes in new construction have lower floor area growth, material requirements, and emissions from construction.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Methods of modifying material flow mode during machining and products formed thereby
Methods of inducing segmented flow in a material in which a ductile flow mode would otherwise occur during machining. A monolayer molecular film is formed on a surface of a body of a material in a state such that the material exhibits ductile flow when subjected to shear. The monolayer molecular film has molecules each having a head group adsorbed to the surface, a terminal group, and a hydrocarbon chain therebetween having a chain length of greater than 6. A surface portion of the body is removed by engaging the body with a tool in a contact region below the surface of the body and moving the tool relative to the body to remove the surface portion and the monolayer molecular film thereon. The monolayer molecular film induces segmented flow in the material during the removing of the surface portion.
Sugihara, Tatsuya↗
A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis
Solar photovoltaics (PV) are the fastest growing renewable energy technology for clean, inexpensive, and sustainable electricity generation. Along with numerous technical roadmaps to improve system cost, performance and reliability, the PV industry should also plan to handle large volumes of silicon panel waste, which is initially estimated to be ~13 million metric tons (MT) by 2050 in the U.S. alone. Understanding the magnitude of material needs and how material flows throughout the PV panel life cycle could respond to design, operational and different end-of-life (EOL) circular pathways will help transition into a circular, resource-conserving economy. Herein, we introduce a dynamic material flow analysis (DMFA) framework based on electricity generation to quantify time-series stocks and flows of bulk PV materials (e.g., solar glass and aluminum frames) throughout the life cycles of utility-scale silicon PV systems in the U.S. in the period 2000-2100. We apply the model to a range of scenarios to understand how material demands depend on selected PV-related parameters, different material circularity strategies, and recent module design trends (e.g., bifacial, frameless). We found that float glass and aluminum in PV installations would likely reach 100 million MT and 12 million MT by 2100, respectively, in the baseline scenario. The most influential parameters for PV installation and subsequent waste reduction are found to be module lifetime, module efficiency, annual degradation, and material reduction. Module recycling and component remanufacturing were found to be the most effective material circularity strategies for waste minimization. Panel reuse has negligible savings on waste under current module efficiencies compared to replacements with newer generations with higher efficiency. Ongoing trends to produce larger power frameless modules could save 10 million MT of glass and ~9 million MT of aluminum. Our results enable advanced planning for future materials needs and provide insight into potential opportunities to minimize waste.
70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗
Dynamic Material Flow Analysis of Silicon Photovoltaic Modules to Support a Circular Economy Transition
Solar photovoltaics (PV) are the fastest growing renewable energy technologies for clean, cheap, and sustainable electricity generation. To prepare for rapid scale-up, the PV industry needs to project material requirements to build out all aspects of the supply chain appropriately and plan to handle large volumes of module waste. Impacts of deploying different material circularity strategies to reduce waste and conserve primary resources need to be quantified to inform sustainable material management. Here, we introduce the photovoltaic dynamic material flow analysis (PV DMFA) model based on PV electricity generation. The model quantifies material flows and stocks in the cradle-to-cradle life cycles of utility-scale c-Si PV systems in the United States through 2100. We present case studies for solar flat glass and aluminum frame materials under various scenarios to project the impacts of PV performance, reliability, and processing parameters, material circularity strategies, and module design shifts. In the absence of circularity measures, ~100 million MT of flat glass and ~12 million MT of aluminum would be needed for PV installations by 2100 to meet projected growth in domestic utility PV demand to nearly 1000 TWh in 2100. With optimistic but feasible improvements in efficiency, reliability, and circularity, material intensity and waste could be reduced by nearly 50%. Efficient module collection, minimally intrusive recycling, and careful scrap handling and cleaning could improve material circularity in the PV value chain. This model serves as a sustainability data support tool that may aid in the circular economy transition for PV systems.
circular economy↗
A Circularity Assessment for Silicon Solar Panels Based on Dynamic Material Flow Analysis: Preprint
Solar photovoltaics (PV) are the fastest growing renewable energy technology for clean, inexpensive, and sustainable electricity generation. Along with numerous technical roadmaps to improve system cost, performance and reliability, the PV industry should also plan to handle large volumes of silicon panel waste, which is initially estimated to be ~13 million metric tons (MT) by 2050 in the U.S. alone. Understanding the magnitude of material needs and how material flows throughout the PV panel life cycle could respond to design, operational and different end-of-life (EOL) circular pathways will help transition into a circular, resource-conserving economy. Herein, we introduce a dynamic material flow analysis (DMFA) framework based on electricity generation to quantify time-series stocks and flows of bulk PV materials (e.g., solar glass and aluminum frames) throughout the life cycles of utility-scale silicon PV systems in the U.S. in the period 2000-2100. We apply the model to a range of scenarios to understand how material demands depend on selected PV-related parameters, different material circularity strategies, and recent module design trends (e.g., bifacial, frameless). We found that float glass and aluminum in PV installations would likely reach 100 million MT and 12 million MT by 2100, respectively, in the baseline scenario. The most influential parameters for PV installation and subsequent waste reduction are found to be module lifetime, module efficiency, annual degradation, and material reduction. Module recycling and component remanufacturing were found to be the most effective material circularity strategies for waste minimization. Panel reuse has negligible savings on waste under current module efficiencies compared to replacements with newer generations with higher efficiency. Ongoing trends to produce larger power frameless modules could save 10 million MT of glass and ~9 million MT of aluminum. Our results enable advanced planning for future materials needs and provide insight into potential opportunities to minimize waste.
circular economy↗
Material flow behavior and microstructural refinement of AA6061 alloy during friction extrusion
In this work we used friction extrusion (FE), a solid phase processing technique, to produce dense, fully consolidated 5?mm rods of aluminum alloy 6061 (AA6061). The combination of large shear stresses and high temperatures at the tool-billet interface during extrusion produced equiaxed, dynamically recrystallized grains and finely distributed precipitates. Texture and microstructure evolution during extrusion was investigated in detail using scanning electron microscopy, electron backscatter diffraction, and transmission electron microscopy. Smoothed particle hydrodynamics simulation was performed to study complex material flow during extrusion. Simulation results suggest spiral material flow during extrusion which corroborated experimental results. Advantages of friction extruded microstructure over conventionally extruded counterparts are also explored using flash annealing for solution treatment followed by artificial aging. Mechanical properties of the as-friction extruded, and the artificially aged specimens were evaluated using tensile testing and compared with conventional extruded material properties.
37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
Material Flow Analysis and Life Cycle Assessment of Polyethylene Terephthalate and Polyolefin Plastics Supply Chains in the United States
Plastics are useful and beneficial materials that contribute to an improved quality of life, yet they generate significant solid wastes and emissions and consume significant energy resources. Systems analysis is incomplete on current linear production systems of plastics supply chains and their associated processes. Our study combines material flow and life cycle assessment data sets of polyethylene terephthalate (PET) and the main polyolefin polymers in the United States, comprising over 70% of plastics flows. This study estimates the total greenhouse gas (GHG) emissions and energy consumption of these supply chains, including transportation and end-of-life processes, lacking in prior studies. Here we calculate annual GHG emissions and energy consumption of these plastic supply chains to be 101 MMT CO 2 -eq and 3248 PJ in 2019, respectively. The GHG emissions of these supply chains represented 1.5% of the total U.S. emissions and 5% of the total U.S. industry-related GHG emissions. The total energy consumption of these supply chains represented 3.1% of the total U.S. energy consumption in 2019. Transportation of PET and polyolefin plastic materials contributes 5% and 2% to the total supply chain GHG emissions and energy consumption, respectively. This baseline study provides a benchmark and enables a comparison to future circular production systems for plastics in the United States.
09 BIOMASS FUELS↗
Supply Chain Energy and Greenhouse Gas Analysis Using the Materials Flows Through Industry (MFI) Tool: Examination of Alternative Technology Scenarios for the U.S. Chemical Sector
Chemical manufacturing is a large and diverse sector of the U.S. economy, with products, fuels, and a wide assortment of materials used daily by both the public and businesses. Currently, several of the largest volume chemicals produced in the United States rely on fossil fuels as a feedstock, energy source, or both. The list of chemicals includes steam cracking products such as ethylene, propylene, benzene, and xylenes as well as products such as ammonia and methanol. The focus for this work is on platform chemicals that are both produced in the largest volume and have a high potential for subsequent processing into more specialized products. In this study, we explore several new pathways that reduce the overall energy consumption and greenhouse gas (GHG) emissions for each product. These pathways include energy efficiency measures applied to existing production methods, the use of bio‐based fuels and/or feedstocks as new production methods, and electrification of high‐energy‐input stages within current production methods. Scenarios for energy demand and GHG reduction were conducted with the National Renewable Energy Laboratory's Materials Flows through Industry tool. Projections of the energy demand and GHG emissions in 2030 and 2050 are included, using grid composition projections from the NREL ReEDS model. The alternative scenarios selected showcase the effect of realistic changes the industry could make, focusing on technologies with a high level of technical readiness.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Supply Chain Energy and Greenhouse Gas Analysis Using the Materials Flows through Industry (MFI) Tool: Examination of Decarbonization Technology Scenarios for the U.S. Glass Manufacturing Sector
Glass manufacturing is a major part of the U.S. economy, and glass products in multiple sectors - flat glass, container glass, and fiberglass - are a part of everyday life. Despite glass manufacturing's long history, there are still many opportunities for glass production to improve in terms of both in overall energy consumption and greenhouse gas (GHG) emission reduction. Scenarios for the flat, container, and fiberglass sectors show the effect that each improvement has on primary energy demand and GHG emissions, starting from an industry baseline that reflects current manufacturing practices. Using the National Renewable Energy Laboratory's Material Flows through Industry tool, multiple scenarios are examined for each glass sector by applying a combination of energy reduction, increased electrification, hydrogen cofiring, a more renewable electric grid, and increased use of cullet. Additional decarbonization options are possible for glass but are left for later analysis due to cost, feasibility, or data issues. Primary energy demand can be reduced by 75%-83% compared to baseline inputs, depending on the sector, and GHG emissions are reduced by 82%-86%. Applying the maximum level of improvements listed here has the potential to save over 300 million GJ and 25 million metric tons of GHGs by 2050.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Material flow visualization during friction stir welding using high-speed X-ray imaging
Not Available
Agiwal, Hemant (ORCID:0000000180516389)↗
Increased material flow throughput in large scale additive manufacturing through movable segmented build platform
An assembly for additive manufacturing includes a build housing including a base, a print head, and a print head support connected to the base for supporting the print head above the base. A driver system is provided for moving the print head and the base relative to one another. A build platform comprising a build support and at least one platen. The build support can be detachably engageable to the housing. The platens can be detachably engageable to the build support. The build support can include registration structure for registering the position of the build support relative to the build housing. A method of additive manufacturing is also disclosed.
Kunc, Vlastimil↗
Flow and arrest in stressed granular materials
Flowing granular materials often abruptly arrest if not driven by sufficient applied stresses. Such abrupt cessation of motion can be economically expensive in industrial materials handling and processing, and is significantly consequential in intermittent geophysical phenomena such as landslides and earthquakes. Using discrete element simulations, we calculate states of steady flow and arrest for granular materials under the conditions of constant applied pressure and shear stress, which are also most relevant in practice. Here the material can dilate or compact, and flow or arrest, in response to the applied stress. Our simulations highlight that under external stress, the intrinsic response of granular materials is characterized by uniquely-defined steady states of flow or arrest, which are highly sensitive to interparticle friction. While the flowing states can be equivalently characterized by volume fraction, coordination number or internal stress ratio, to characterize the states of shear arrest, one needs to also consider the structural anisotropy in the contact network. Here, we highlight the role of dilation in the flow-arrest transition, and discuss our findings in the context of rheological transitions in granular materials.
36 MATERIALS SCIENCE↗
Energy & Materials Resource Flows
This poster presents on flows of resources that support manufacturing, including flows of energy and materials. It highlights the recent and current strategic analysis efforts such as energy and carbon footprints, case studies showing the interconnectedness between sectors and global perspective and competitiveness, NREL's Materials Flows through Industry (MFI) tool; and our big impact report on Sustainable Manufacturing and Circular Economy.
energy↗
Organic anolyte materials for flow batteries
Organic anolyte materials for redox flow batteries and redox flow batteries containing organic anolyte materials are disclosed.
Sanford, Melanie S.↗