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The 2018 Industry Energy Data Book summarizes the status of, and it identifies the key trends in energy use and its underlying economic drivers across the four industrial subsectors: agriculture, construction, manufacturing, and mining.
The Materials Flows through Industry (MFI) tool is a supply chain modeling tool developed at the National Renewable Energy Laboratory (NREL) with funding from the Department of Energy's Advanced Manufacturing Office. MFI was created to identify and analyze opportunities to reduce the energy and carbon intensities of the U.S. industrial sector (Hanes and Carpenter 2017). In this work, we present an overview of the MFI tool's structure and capabilities, as well as the results of using MFI to analyze a novel NREL-developed process to 'upcycle' PET plastic into higher-value composite materials (Rorrer et al. 2019). This process combines recycled PET (rPET) plastic with inputs that can be derived from biomass, including muconic acid, acrylic acid, and ethylene glycol, to chemically break down the plastic back to its monomers in a process called glycolization. Then, repolymerization and the application of fiberglass yields the valuable glass fiber reinforced plastic (GFRP) composite, a performance material used in the manufacture of wind turbine blades, boat hulls, and other applications. This rPET-derived GFRP was found to have superior strength and fiberglass adhesion compared to conventional GFRP formulations. Our findings indicate that this GFRP production process, were it to be widely commercialized beyond its current lab-scale, could potentially reduce the fossil energy intensity of the GFRP supply chain by between 37% and 58% compared to the conventional method of GFRP manufacture from fossil-derived inputs. We also estimate potential supply chain greenhouse gas (GHG) emissions reductions between 30% and 40% from this process. Scaling these GHG offset estimates up to annual GFRP production in the U.S. would be roughly equivalent to removing between 150,000 and 200,000 vehicles from U.S. roads. These ranges of impact estimates represent the range of differences associated with the various economic allocation methods we have assumed for the intensity contributions from the first life of the PET plastic. Following Shen et al. (2010), we derive economic allocation factors from the current price ratios of clear- and green-colored recycled PET plastic to virgin PET resin ('waste-valuation' approach) or assume them to be zero in a more simplistic allocation ('cutoff' approach). Future work involving the MFI modeling tool will also be discussed, including preliminary results comparing the energy intensity of conventional and bio-based nylons manufacturing. Attendees will also be encouraged to conduct MFI supply chain modeling of their own by requesting a user account on the MFI web application, which is freely available to the public at the following address: https://mfitool.nrel.gov.
New and existing factories that produce and deliver factory-built housing can benefit from construction process simulation modeling to explore the integration of Lean principles in their operations. Construction process simulation modeling provides digital or virtual recreations of the real-world factory environments to visualize, quantify, analyze, and optimize their underlying behavior, including factory productivity, material flow, labor dynamics, bottlenecks, and work scope. One of the key benefits of process simulation modeling is the ability to create and compare "what-if" scenarios, including integrating Lean principles such as reducing waste (for example, transportation, waiting), line balancing, and just-in-time concepts. In general, three process simulation methods are widely used: discrete event simulation (DES), agentbased modeling (ABM), and system dynamics (SD). Myriad process simulation software also is available, but depending on the industry, complexity of the system, and purposes of the simulation, some software might be more appropriate. Similar to how computer-aided design (CAD) software such as AutoCAD and Rhinoceros enable building design of modular or factory-built housing, process simulation modeling software such as jStrobe, ProModel, and AnyLogic can enable factory design of new and existing factories to deliver modular affordable housing at scale, as opposed to traditional site-built construction. Software with DES capabilities can help generate a process model that is a logical representation of resources and activities in a factory. Software with CAD-DES integration can leverage product-process data integration to help spatially visualize a DES model of the factory in the CAD environment. Software with multimethod simulation capabilities, widely used in the manufacturing industry, brings together DES, ABM, and SD in a single platform that allows visualization, quantification, analyses, and optimization at varying data fidelities. Near-real-time data from an existing factory can be directly plugged into multimethod simulation software so that the construction process simulation model is a near-accurate representation of the real-world factory conditions. This report provides insights into the use of simulation as an aid to integrate Lean concepts in factories, including guidelines for selecting the appropriate process simulation modeling method and software. These insights have been developed as part of ongoing process simulation modeling research, development, and demonstration projects at the U.S. Department of Housing and Urban Development, the U.S. Department of Energy, and the National Renewable Energy Laboratory focused on how process simulation models can enable better integration of resilience, energy efficiency, and low-carbon design strategies.
When deploying software based systems, such as, digital instrumentation and controls for the nuclear industry, it is vital to include cyber security assessment as part of architecture and development process. When integrating and delivering software-intensive systems for the nuclear industry, engineering teams should make use of a secure, requirements driven, software development life cycle, ensuring security compliance and optimum return on investment. Reliability protections, data loss prevention, and privacy enforcement provide a strong case for installing strict cyber security policies. (authors)
CEA and AREVA-NC have developed and used a depletion code named CESAR for 30 years. This user-friendly industrial tool provides fast characterizations for all types of nuclear fuel (PWR / UOX or MOX or reprocess Uranium, BWR / UOX or MOX, MTR and SFR) and the wastes associated. CESAR can evaluate 100 heavy nuclides, 200 fission products and 150 activation products (with Helium and Tritium formation). It can also characterize the structural material of the fuel (Zircalloy, stainless steel, M5 alloy). CESAR provides depletion calculations for any reactor irradiation history and from 3 months to 1 million years of cooling time. CESAR5.3 is based on the latest calculation schemes recommended by the CEA and on an international nuclear data base (JEFF-3.1.1). It is constantly checked against the CEA referenced and qualified depletion code DARWIN. CESAR incorporates the CEA qualification based on the dissolution analyses of fuel rod samples and the 'La Hague' reprocessing plant feedback experience. AREVA-NC uses CESAR intensively at 'La Hague' plant, not only for prospective studies but also for characterizations at different industrial facilities all along the reprocessing process and waste conditioning (near 150 000 calculations per year). CESAR is the reference code for AREVA-NC. CESAR is used directly or indirectly with other software, data bank or special equipment in many parts of the La Hague plants. The great flexibility of CESAR has rapidly interested other projects. CESAR became a 'tool' directly integrated in some other softwares. Finally, coupled with a Graphical User Interface, it can be easily used independently, responding to many needs for prospective studies as a support for nuclear facilities or transport. An English version is available. For the principal isotopes of U and Pu, CESAR5 benefits from the CEA experimental validation for the PWR UOX fuels, up to a burnup of 60 GWd/t and for PWR MOX fuels, up to 45 GWd/t. CESAR version 5.3 uses the CEA reference calculation codes for neutron physics with the JEFF-3.1.1 nuclear data set. (authors)
Malicious use of radioactive sources can involve dispersal of that material through an explosive device. There has been recognition of the threat posed by the potential malicious misuse of NDT radioactive source by terrorists. The dispersal of radioactive material using conventional explosives, referred to as a 'dirty bomb', could create considerable panic, disruption and area access denial in an urban environment. However, as it is still a relatively new topic among regulators, users, and transport and storage operators worldwide, international assistance and cooperation in developing the necessary regulatory and security infrastructure is required. The most important action in reducing the risk of radiological terrorism is to increase the security of radioactive sources. This paper presents safety and security considerations for the transport and site storage of the industrial radiography sources as per national regulations entitled 'Nuclear Safety and Radiation Control Rules-1997'.The main emphasis was put on the stages of some safety and security actions in order to prevent theft, sabotage or other malicious acts during the transport of the packages. As a conclusion it must be mentioned that both safety and security considerations are very important aspects that must be taking in account for the transport and site storage of radioactive sources used in the practice of industrial radiography. (authors)
The South West Nuclear Hub has joined with its industrial partners to engage with the public about the pros and cons of nuclear power, and open a balanced and evidence-based dialogue around common areas of concern, such as nuclear safety and nuclear waste. This programme of industrial engagement must continue into the future if we are to understand and effectively address those concerns, and make the UK's nuclear renaissance work for all. (authors)
There is a requirement to measure a variety of challenging radioactive waste forms generated by the Chinese nuclear industry. These range from low activity waste to high activity waste with a high content of Cs-137 and waste in high density 200 litre drums. This paper describes the design, development and testing of an updated and automated Wide Range Segmented Gamma Scanner (WR-SGS) specifically configured for Chinese nuclear industry radioactive waste measuring requirements. The instrument retains the capabilities of the original SGS developed by Parker and Martin at the Los Alamos National Laboratory and now widely used for radioactive waste assay. It also incorporates additional features to improve measurement efficiency and reduce cost. These features include continuous helical scanning of the waste drum, and separate lifting pillars to lift the detector and the transmission source. In place of a transmission source shutter mechanism, the source is placed in a shielded safe when not in use. The design also incorporates a variable aperture collimator, and tungsten filters that can be deployed for the measurement of high activity, high dose-rate drums. Updated motion control electronics, based on the use of a programed logic controller have been incorporated to address potential future obsolescence. The WR-SGS employs a 40% high purity Germanium detector with electro-mechanical cooling and state of the art digital spectroscopy counting electronics for gamma ray spectrum data acquisition. Testing of the unit has been performed with both point sources and rod sources, which are traceable to international standards. Typical test drums, each with six distributed re-entrant tubes and with different density matrices, have been employed with the rod sources to validate both the calibration and the measurement performance of the WR-SGS for drums of different density. The measurement results have been compared with the reference decay corrected activity values and very good agreement is achieved, confirming the measurement performance of the instrument. (authors)
Many engineering employers are finding that graduates are not sufficiently equipped to begin contributing productively when they exit a 4-year institution and enter the workforce. The Intern Professional Development Center (IPDC) is a proposed business model that exposes engineering undergraduates to industry-relevant knowledge, while providing them with working experience during their degree. Using a tri-stage approach, the IPDC engages with students early in their academic careers, provides continuous training and development opportunities, and finally connects the students with potential employers. The two topics most commonly under-represented in engineering programs are: - Familiarity with drafting software - Knowledge of relevant codes and standards. The Intern Professional Development Center (IPDC): A tri-stage solution for recruiting, training, and encouraging the workforce of tomorrow. An IPDC allows students to be active members of industry during their undergraduate careers, leading to: - Improved local talent retention; - Improved graduation and academic performance statistics; - Near-guarantee for post-graduation employment. In March of 2019, the first IPDC prototype began operating in the Tri-Cities, Washington. Since then, 3 undergraduate students have entered the IPDC at Stage 2, beginning with the standard training and professional development. Of those 3 students, 2 have already moved on to Stage 3, with successful ongoing internships with local employers. At a performance review for one of the IPDC's Stage 3 students after 90 days of employment, the direct manager said: 'How soon can we get another one?'.
In the nuclear industry, risk monitors are intended to provide a point-in-time estimate of the system risk given the current plant configuration. Current risk monitors are limited in that they do not properly take into account the deteriorating states of plant equipment, which are unit-specific. Current approaches to computing risk monitors use probabilistic risk assessment (PRA) techniques, but the assessment is typically a snapshot in time. Living PRA models attempt to address limitations of traditional PRA models in a limited sense by including temporary changes in plant and system configurations. However, information on plant component condition is not considered. This often leaves risk monitors using living PRA models incapable of conducting evaluations with dynamic degradation scenarios evolving over time. There is a need to develop enabling approaches to solidify risk monitors to provide time- and condition-dependent risk by integrating traditional PRA models with condition monitoring and prognostic techniques. This paper presents an estimation of system risk evolution over time by integrating plant risk monitoring data with dynamic PRA methods that incorporate aging and degradation. Several online, nondestructive approaches have been developed for diagnosing plant component conditions in the nuclear industry, i.e., using a condition indication index, vibration analysis, current signatures, and operational history . In this work, the component performance measures at U.S. commercial nuclear power plants are incorporated within the dynamic PRA methodologies to provide better estimates of the probability of failures. Aging and degradation are modeled within the Level 1 PRA framework, are applied to several failure modes of pumps, and can be extended to a range of components, namely, valves, generators, batteries, and pipes. (authors)
Industrial loads have significant energy resilience requirements, which is one reason distributed wind may be a good option to help provide generation for these facilities. This fact sheet provides an overview of industrial load energy and resilience needs, and discusses why distributed wind may be a good option to provide onsite power for these facilities.
Due to the deep socioeconomic implications, induced seismicity is a timely and increasingly relevant topic of interest for the general public. Cases of induced seismicity have a global distribution and involve a large number of industrial operations, with many documented cases from as far back to the beginning of the twentieth century. However, the sparse and fragmented documentation available makes it difficult to have a clear picture on our understanding of the physical phenomenon and consequently in our ability to mitigate the risk associated with induced seismicity. This review presents a unified and concise summary of the still open questions related to monitoring, discrimination, and management of induced seismicity in the European context and, when possible, provides potential answers. Lastly, we further discuss selected critical European cases of induced seismicity, which led to the suspension or reduction of the related industrial activities.
Efficient CO 2 utilization is key to limit global climate change. Carbon monoxide, which is a crucial feedstock for chemical synthesis, can be produced by splitting CO 2 . However, existing thermochemical routes are energy intensive requiring high operating temperatures. A hybrid redox process (HRP) involving CO 2 –to–CO conversion using a lattice oxygen–deprived redox catalyst at relatively low temperatures (<700 °C) is reported. The lattice oxygen of the redox catalyst, restored during CO 2 –splitting, is subsequently used to convert methane to syngas. Operated at temperatures significantly lower than a number of industrial waste heat sources, this cyclic redox process allows for efficient waste heat–utilization to convert CO 2 . To enable the low temperature operation, lanthanum modified ceria (1:1 Ce:La) promoted by rhodium (0.5 wt%) is reported as an effective redox catalyst. Near–complete CO 2 conversion with a syngas yield of up to 83% at low temperatures is achieved using Rh–promoted LaCeO 4–x . While La improves low–temperature bulk redox properties of ceria, Rh considerably enhances the surface catalytic properties for methane activation. Density functional theory calculations further illustrate the underlying functions of La–substitution. In conclusion, the highly effective redox catalyst and HRP scheme provide a potentially attractive route for chemical production using CO 2 , industrial waste heat, and methane, with appreciably lowered CO 2 emissions.
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.
Rechargeable Zn-ion batteries (RZIBs) are considered to be promising energy storage systems for large-scale applications owing to their relatively high energy densities and inherently low costs, environmental benignity, as well as safety. With increasing interest and effort being devoted to this field, RZIBs are being tremendously advanced and are very likely to be commercialized in the near future. However, some challenges remain that need to be addressed. Moreover, reported results are quite often overstated through artificial exaggeration and cannot be translated to industrial applications as they were obtained under ideal testing conditions. Therefore, in this perspective, here we discuss key parameters that need to be carefully considered when translating laboratory-developed RZIBs into commercial reality. We also present a critical mini-review on RZIBs and devote effort to issues that are overlooked in academic research. We believe that this perspective provides new or seldom-discussed insight for future work and bridges the gap between academia and industry.
Fused cast alumina (FCA) has been and continues to be used as a refractory material in energy intensive industries such as glass melting and chemical processing. In-service degradation due to high temperature exposure in harsh environment affects the designed furnace thermal profiles and energy consumption. Phase transformation may occur at the refractory hot face during glass melting altering the properties. Three FCA blocks recovered from industrial furnaces were investigated in this study. The as-received FCA consists primarily of a mixture of alpha (α) and beta (β) alumina that has a thermal conductivity value of 5–6 W/mK. The Hot Disk method was used to obtain thermal conductivity directly on the refractory blocks. At the hot face, a transformation from β to α alumina occurred and was confirmed by an X-ray diffraction study. Thermal conductivity measurements as a function of position also showed a clear transition from β to α alumina at both ends of a complete block with no voids. Thermal conductivity of the α alumina tripled compared to β alumina. This study provides important information of heat transfer and thermal conductivity evolution to refractory manufacturers and users.
Nanoparticle-supported Pt and Pd catalysts are employed industrially to convert CO and hydrocarbon residue from incomplete diesel fuel combustion into more environmentally-benign products. However, these catalysts deactivate over time due to sintering, especially for Pt nanoparticles which readily generate volatile species under high operating temperatures. Here, we turned the detrimental vapor-mediated sintering of Pt into an advantage by using a physical mixture of Pt and Pd catalysts prepared using a raspberry-colloid-templating (RCT) method. The RCT method produced Pt/Al 2 O 3 and Pd/Al 2 O 3 catalysts with partially embedded NPs to inhibit surface-mediated sintering pathways. As validated using an industry-defined emission control test protocol, aging a physical mixture of Pt/Al 2 O 3 and Pd/Al 2 O 3 at high temperature produced an alloyed PtPd/Al 2 O 3 catalyst that outperformed the fresh catalyst mixture and both individual catalysts for hydrocarbon conversion, while exhibiting high catalytic stability and resistance to sintering and to SO 2 poisoning. X-ray photoelectron spectroscopy revealed that in the aged catalyst mixture, half of the Pd content existed in the more active metallic state, compared to the less active oxide forms in the fresh mixture and both individual catalysts, explaining the unusual activity enhancement. Our results represent a practical approach to producing active and stable PtPd/Al 2 O 3 diesel oxidation catalysts for emission control applications.
Here, early motivation and use of energetic materials in the Western World by Alfred Nobel was intended to facilitate mining, construction, and demolition activities. The motivation for the work was the recognized need for a safer energetic material as an alternate to unstabilized nitroglycerine. The invention of dynamite by Nobel was widely adopted in the civilian world and brought a fortune to Nobel, resulting in the formation of the annual Nobel Prize awards, recognizing significant achievements across many fields of endeavour. Nonetheless, further development of energetics was primarily motivated by and funded for military purposes, rather than civilian usage. And indeed much investment has been given to the development and characterization of military energetics and their application. An example application is the precision shaped charge, primarily developed as a means of focusing energy in a narrow metallic jet for deep penetration of heavy armor. However, the largest costumer today and for many years for shaped charges is not the military, but rather the oil and gas industry, which has adapted the military technology for perforation of oil and gas wells. While there are similar aspects to desired penetration capabilities in both applications, there are enough differences to warrant energetics R & D focused on oil and gas industry needs.