Study of a dry room in a battery manufacturing plant using a process model
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Ahmed, Shabbir↗
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Results for “MANUFACTURING PLANTS”
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Simulation-Based Improvement in the Models for Tool-Inventory Management at Manufacturing Plants
Tool-inventory management at manufacturing plants is of great theoretical and practical importance. The main management problem here is that it is impossible to take precise account of all the changes in the tool stock for the basic production process. The relevant dynamics may be random as a consequence of the simultaneous action of several factors. In the present work, attention focuses on statistical modeling, which allows many factors to be taken into account and permits the creation of a more precise model of planning, production, and tool consumption at an industrial enterprise.
42 ENGINEERING↗
Manufacturing Readiness and Cost Impacts for PEM Stack and Balance of Plant
The results of two Manufacturing Readiness Assessments of PEM fuel cell stacks and material handling equipment (MHE) and backup power (BUP) PEM fuel cell systems are given. Design modifications of fuel cell systems were made because the initial, 2008 designs did not fully meet the operational requirements of the markets. This situation indicates the 2008 risk elements were overstated.For 2010 BUP and MHE fuel cell systems, manufacturers had not reached the Low Rate Initial Production (LRIP) defined in the 2008 MRA Report at 1,000 units per year per manufacturer.For fuel cell stacks, LRIP was demonstrated by more than one manufacturer.The federal tax incentive program has compensated for the initial high cost of fuel cell systems.The Balance-of-Plant (BOP) has not evolved as rapidly as the PEM fuel cell stack manufacturing readiness.The BOP in 2014 is as costly as the fuel cell stack for MHE applications.
30 DIRECT ENERGY CONVERSION↗
Plant Water Profiler: A Tool for Understanding Water Use, Cost and Savings Potential for Manufacturing Plants
In the 1746 Poor Richard’s Almanack, Benjamin Franklin published “When the well’s dry, we know the worth of water” (Franklin, 1746); industrial water users have begun to see the truth in these words as they examine the potential and reality of water scarcity becoming a significant business risk. Through the authors’ interactions with manufacturers via the U.S. Department of Energy’s Better Plants program and Strategic Analysis projects, they realized that manufacturing facilities often do not fully understand the risks to the water supply and the consequential risks to their business. The authors’ also noticed that many facilities do not know how their water is used (baselining), how they compare with their peers (benchmarking), the actual cost impacts of water use (true cost of water), and potential areas for water savings. This results in a lack of motivation and ability to identify and implement effective water-efficiency measures.The Plant Water Profiler Tool (PWP) was created to help manufacturing plant management address these issues by identifying and accounting for water use in manufacturing operations, helping determine the true cost of water, and providing some high-level estimates for peer comparison. The PWP uses a water mass balance and common engineering equations to estimate water use by each of the facility’s systems (e.g., differentiating process water use from cooling and restroom water use), even when no submetering data is available. This new tool also helps users identify possible areas for water savings and associated water and energy cost savings, making it a potentially useful resource for corporations conducting water assessments. Additionally, governments and private organizations can use the methodology behind this tool to design a survey to help build a database of industrial water use. This paper and corresponding presentation provide an overview of current industrial water use practices and tools, as well as the value of determining the true cost of water. It also briefly describes the methodology behind the tool, then focuses on its functionality through an industrial case study and lessons learned from implementing the case study.
Armstrong, Kristina O.↗
Plant Water Profiler: A Water Balance and True Cost of Water Calculator for Manufacturing Plants
As the uncertainty of a sustained water supply, regulatory constraints, competition among end users, and public scrutiny increases, a growing number of manufacturing sectors are adapting to current and emerging water-related risks by optimizing productivity and reducing waste. As a step toward increasing water use efficiency and making informed business decisions, corporations must make an effort to understand and track their water demands, losses, and costs associated with each subsystem within their facilities. Manufacturers are often unaware of the “true cost of water” (i.e., the total costs associated with procurement, treatment, and consumption of water, and wastewater disposal), which reduces the visibility of the actual impact of water-saving measures. To help manufacturers account for water procurement and use in manufacturing operations, quantify the true cost of water, and identify potential areas for water and associated energy cost savings, an open access tool—Plant Water Profiler (PWP)—was developed. The tool is based on water mass balance analysis and has been adopted as the core analysis tool for plant water use assessments, Water In-Plant Training (Water INPLT), as part of the US Department of Energy’s Better Plants program. During three pilot INPLTs conducted in 2019 at three manufacturing facilities, the PWP tool allowed users to understand water flows within the facilities and provided additional capabilities to analyze their water use. This paper describes the methodology behind the PWP tool and its implementation through pilot Water INPLT trainings delivered in three manufacturing facilities in the United States. The three case studies demonstrate opportunities to improve water efficiency and reduce associated costs and the challenges encountered in three different manufacturing sectors.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Onsite 40-kilowatt fuel cell power plant manufacturing and field test program
A joint Gas Research Institute and U.S. Department of Energy Program was initiated in 1982 to evaluate the use of fuel cell power systems for on-site energy service. Forty-six 40 kW fuel cell power plants were manufactured at the United Technologies Corporation facility in South Windsor, Connecticut, and are being delivered to host utilities and other program participants in the United States and Japan for field testing. The construction of the 46 fully-integrated power plants was completed in January 1985 within the constraints of the contract plan. The program has provided significant experience in the manufacture, acceptance testing, deployment, and support of on-site fuel cell systems. Initial field test results also show that these experimental power plants meet the performance and environmental requirements of a commercial specification. This Interim Report encompasses the design and manufacturing phases of the 40 kW Power Plant Manufacturing and Field Test program. The contract between UTC and NASA also provides UTC field engineering support to the host utilities, training programs and associated manuals for utility operating and maintenance personnel, spare parts support for a defined test period, and testing at UTC of a power plant made available from a preceding program phase. These activities are ongoing and will be reported subsequently.
Source record↗
Gluing Practice at Aircraft Manufacturing Plants
This report records observations and recommendations resulting from an inspection trip to representative aircraft manufacturing establishments and repair stations. This inspection was made for the Navy Department and was specifically in reference to gluing practice at the various places visited. The period of the visits was between November 23, 1926 and February 16, 1927.
GLUING↗
Challenges in Tracking Waste Reduction Performance Improvement in Manufacturing Plants
The recently released Circularity Gap Report 2023 by the Circle Economy Foundation states that the circularity score for the global economy is declining. The US Environmental Protection Agency (EPA) tracked municipal solid waste from 1960 to 2018 and found that 50% of the waste was destined for landfills. EPA estimates that US industry is responsible for 2.7 Gt of solid nonhazardous waste annually in the US mostly linear economy model. The circular economy framework aims to decouple economic value generation from the extraction of virgin materials from nature. The linear model of material extraction and disposal at the end of life is highly unsustainable. Manufacturing companies are adopting ambitious waste reduction targets to achieve sustainability. Through the Better Plants program, US DOE has established the Waste Reduction Network, which offers technical assistance to partners to achieve their ambitious waste reduction goals. Basic requirements of establishing a target include identifying a baseline, quantifying waste performance, and measuring progress over time. One problem faced by industry is unstandardized metrics for quantifying waste performance that may not be well suited to demonstrate progress. This paper studies traditional methods used to measure waste performance and highlights advantages, disadvantages, and limitations of each method. It also examines the suitability of applying the methods in different manufacturing circumstances. Finally, the paper presents a case study of a large manufacturer that faced inconsistencies in its tracked measurement metric. A solution was proposed and implemented to alter the methodology to enable more accurate waste performance tracking against a baseline.
circular economy↗
Solar Heating and Cooling for a Controls Manufacturing Plant Lumberton, New Jersey
Comprehensive report documents computer-controlled system which has separate solar-collector and cooling-tower areas located away from building and is completely computer controlled. System description, test data, major problems and resolution, performance, operation and maintenance, manufacturer's literature and drawing comprise part of 257-page report.
Source record↗
Challenges in Tracking Waste Reduction Performance Improvement in Manufacturing Plants
The recently released Circularity Gap Report 2023 by Circle Economy Foundation found that the circularity score for the global economy is declining. This indicates that material extraction from virgin sources is climbing over earlier years. As per data released by US Geological Survey, material use in the US economy has increased exponentially with the expanding US economy over last century. EPA tracked municipal solid waste from 1960 to 2018 and found that 50% of the waste is destined for landfills. EPA estimates that US industry is responsible for 2.7 billion ton of solid non-hazardous waste annually in our mostly linear economy model. The circular economy framework aims at decoupling economic value generation from virgin materials extraction from nature. The linear model of material extraction and disposal at end of life is highly unsustainable. Manufacturing companies have realized this and in their commitments to sustainability are adopting ambitious waste reduction targets. Through Better Plants program US Department of Energy has established Waste Reduction Network where it is offering technical assistance to partners to achieve these ambitious waste reduction goals. Basic requirements of establishing a target include identifying a baseline, quantifying waste performance, and measuring progress over time. One problem faced by industry is the unstandardized metrics to quantify waste performance that may not be well suited to demonstrate progress. In this paper, we research methods traditionally used to measure waste performance and highlight advantages, gaps and limitations of each method. Suitability of the methods applicable to different manufacturing circumstances are also examined. Finally, we present a case study of a large manufacturer that faced inconsistencies in their tracked measurement metric. A solution was proposed to alter the methodology to enable more accurate waste performance tracking against a baseline.
Chaudhari, Subodh↗
Toward the application of the Risk-Based Maintenance approach to a hydrogen-fueled manufacturing plant
Safety, reliability, and maintenance of hydrogen-based equipment, including Risk-Based Maintenance (RBM), have recently gained increasing attention, as hydrogen, while key to decarbonizing hard-to-abate sectors, raises safety concerns. However, two literature gaps limit the development of risk-based strategies for hydrogen technologies. First, existing RBM methodologies do not account for hydrogen-specific components, such as electrolyzers, which differ from conventional equipment. Second, available studies on electrolyzer reliability remain largely qualitative or laboratory-scale. This study addresses these gaps by proposing an adapted RBM methodology tailored to hydrogen-fueled manufacturing facilities. Integrating qualitative tools (e.g., FMEA) with probabilistic models (e.g., Bayesian Networks) enables comprehensive hazardous scenarios identification and likelihood estimation. A conceptual layout of a glass furnace supplied by a 3 MW PEM electrolyzer is considered as a case study to demonstrate the feasibility of the adapted RBM framework in identifying high-risk components and enabling maintenance prioritization, potentially improving plant safety.
08 HYDROGEN↗
Field Validation of Electrochemical Water Filtration System on an Open Loop Cooling Tower at Nissan Manufacturing Plant in Canton, Mississippi
The U.S. Department of Energy Industrial Efficiency and Decarbonization Office’s Industrial Technology Validation (ITV) program aims to identify and demonstrate the performance of new, emerging, and underutilized technologies in the industrial sector to help inform decisions towards accelerating commercialization and deployment. This ITV demonstration investigated the performance of an early-commercial electrochemical water treatment technology on a cooling tower at an automotive plant. Cooling towers are vital equipment for dissipating heat from industrial processes, but they face challenges related to scaling, corrosion, and the growth of biological contaminants. Effective cooling tower water treatment is therefore essential in reducing these contaminants and other total suspended solids (TSS) and total dissolved solids (TDS). Various treatment systems, such as sand-based filters, centrifugal separators, and disc filters are available, each having its advantages and drawbacks. ElectroCell Systems, a filtration technology provider, offers an electrochemistry-based water treatment system that is skid-mounted and can be configured as a side-stream filtration system.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
Solar heating for an electronics manufacturing plant--Blue Earth, Minnesota
Partial space heating for 97,000 square foot plant is supplied by 360 flat plate solar collectors; energy is sorted as heat in indoor 20,000 gallon water tank. System includes all necessary control electronics for year round operation. During December 1978, solar energy supplied 24.4 percent of building's space heating load.
Source record↗
Optimization-Based Production Scheduling for Complex Manufacturing Plants Delivered as a Service using High Performance Computing Architecture & Algorithms. Final report, SBIR Phase I
Explore the source record for details and available documents.
HANAGANDI, VIJAY↗
ISS Fiber Optic Failure Investigation Root Cause Report
In August of 1999, Boeing Corporation (Boeing) engineers began investigating failures of optical fiber being used on International Space Station flight hardware. Catastrophic failures of the fiber were linked to a defect in the glass fiber. Following several meetings of Boeing and NASA engineers and managers, Boeing created and led an investigation team, which examined the reliability of the cable installed in the U.S. Lab. NASA Goddard Space Flight Center's Components Technologies and Radiation Effects Branch (GSFC) led a team investigating the root cause of the failures. Information was gathered from: regular telecons and other communications with the investigation team, investigative trips to the cable distributor's plant, the cable manufacturing plant and the fiber manufacturing plant (including a review of build records), destructive and non-destructive testing, and expertise supplied by scientists from Dupont, and Lucent-Bell Laboratories. Several theories were established early on which were not able to completely address the destructive physical analysis and experiential evidence. Lucent suggested hydrofluoric acid (HF) etching of the glass and successfully duplicated the "rocket engine" defect. Strength testing coupled with examination of the low strength break sites linked features in the polyimide coating with latent defect sites. The information provided below explains what was learned about the susceptibility of the pre-cabled fiber to failure when cabled as it was for Space Station and the nature of the latent defects.
Leidecker, Henning↗
U.S. Wind Energy Manufacturing and Supply Chain: A Competitiveness Analysis
The goal of the project was to develop a greater understanding of the key factors determining wind energy component manufacturing costs and pricing on a global basis in order to enhance the competitiveness of U.S. manufacturers, and to reduce installed systems cost. Multiple stakeholders including DOE, turbine OEMs, and large component manufactures will all benefit by better understanding the factors determining domestic competitiveness in the emerging offshore and next generation land-based wind industries. Major objectives of this project were to: 1. Carry out global cost and process comparisons for 5MW jacket foundations, blades, towers, and permanent magnet generators; 2. Assess U.S. manufacturers’ competitiveness and potential for cost reduction; 3. Facilitate informed decision-making on investments in U.S. manufacturing; 4. Develop an industry scorecard representing the readiness of the U.S. manufacturers’ to produce components for the next generations of wind turbines, nominally 3MW land-based and 5MW offshore; 5. Disseminate results through the GLWN Wind Supply Chain GIS Map, a free website that is the most comprehensive public database of U.S. wind energy suppliers; 6. Identify areas and develop recommendations to DOE on potential R&D areas to target for increasing domestic manufacturing competitiveness, per DOE’s Clean Energy Manufacturing Initiative (CEMI). Lists of Deliverables 1. Cost Breakdown Competitive Analyses of four product categories: tower, jacket foundation, blade, and permanent magnet (PM) generator. The cost breakdown for each component includes a complete Bill of Materials with net weights; general process steps for labor; and burden adjusted by each manufacturer for their process categories of SGA (sales general and administrative), engineering, logistics cost to a common U.S. port, and profit. 2. Value Stream Map Competitiveness Analysis: A tool that illustrates both information and material flow from the point of getting a customer order at the manufacturing plant; to the orders being forwarded by the manufacturing plant to the material suppliers; to the material being received at the manufacturing plant and processed through the system; to the final product being shipped to the Customer. 3. Competitiveness Scorecard: GLWN developed a Wind Industry Supply Chain Scorecard that reflects U.S. component manufacturers’ readiness to supply the next generation wind turbines, 3MW and 5MW, for land-based and offshore applications. 4. Wind Supply Chain Database & Map: Expand the current GLWN GIS Wind Supply Chain Map to include offshore elements. This is an on-line, free access, wind supply chain map that provides a platform for identifying active and emerging suppliers for the land-based and offshore wind industry, including turbine component manufacturers and wind farm construction service suppliers.
17 WIND ENERGY↗
Manufacturing Cost Levelization Model – A User’s Guide
The Manufacturing Cost Levelization Model is a cost-performance techno-economic model that estimates total large-scale manufacturing costs for necessary to produce a given product. It is designed to provide production cost estimates for technology researchers to help guide technology research and development towards an eventual cost-effective product. The model presented in this user’s guide is generic and can be tailored to the manufacturing of any product, including the generation of electricity (as a product). This flexibility, however, requires the user to develop the processes and process efficiencies that represents a full-scale manufacturing facility. The generic model is comprised of several modules that estimate variable costs (material, labor, and operating), fixed costs (capital & maintenance), financing structures (debt and equity financing), and tax implications (taxable income after equipment and building depreciation, debt interest payments, and expenses) of a notional manufacturing plant. A cash-flow method is used to estimate a selling price necessary for the manufacturing plant to recover its total cost of production. A levelized unit sales price ($ per unit of product) is determined by dividing the net-present value of the manufacturing plant’s expenses ($) by the net present value of its product output. A user defined production schedule drives the cash-flow method that determines the levelized unit price. In addition, an analyst can increase the levelized unit price to include a gross profit margin to estimate a product sales price. This model allows an analyst to understand the effect that any input variables could have on the cost of manufacturing a product. In addition, the tool is able to perform sensitivity analysis, which can be used to identify the key variables and assumptions that have the greatest influence on the levelized costs. This component is intended to help technology researchers focus their research attention on tasks that offer the greatest opportunities for cost reduction early in the research and development stages of technology invention.
29 ENERGY PLANNING, POLICY, AND ECONOMY↗
Nuclear-Renewable Energy Systems Secondary Product Market Analysis Study
In order to properly create a program surrounding the development of any technological concept it is necessary to fully understand the market in which it is being developed. In the case of Integrated Nuclear-Renewable Hybrid Energy Systems (HES), there are two economic markets in which it must be able to participate in: the electricity market and the secondary product market associated with the specific system. The purpose of the present report is to characterize the secondary product market in the U.S. and to provide recommendations for further developing the HES program. While HESs have been discussed in depth in many other reports, it is helpful to discuss them briefly in the present work [REF]. The concept of the HES can be deduced to a system, featuring a combination of a nuclear power plant, a renewable energy source, and an industrial manufacturing plant . The system is designed in a fashion that allows it either to produce electricity or to manufacture a secondary product as needed. The primary benefit of this concept lies in its ability to maximize economic performance of the integrated system and to manufacture products in a carbon-free manner. A secondary benefit is the enhanced supply-side flexibility gained by allowing the HES to economically provide grid services. A key tenant to nuclear power plant economics in today’s electricity market is their ability to operate at a very high capacity factor. Unfortunately, in regions with a high penetration of renewable energy, the carbon free energy produced by nuclear power may not be needed at all times. This forces the nuclear power plant to find a user for its excess capacity. This may include paying the electric grid to find a user, releasing energy to the environment by ‘dumping steam’, or reducing power. If the plant is unable to economically or safely do any of these actions, the plant is at risk of being shutdown. In order to allow for nuclear power plants to continue to contribute carbon free electricity to the grid in a future with high renewable energy penetration, HESs allow for excess capacity to be diverted to a chemical process. If the chemical products sold on the market replace those sold previously – which would be the case if a currently operating manufacturing plant was modified to be a HES component – then the products would now be produced with reduced emission of carbon and other greenhouse gases. There are several key economic barriers that must be surmounted for HESs to be developed. The two primary barriers are the increased capital cost associated with coupling and controlling the HES components and the decreased utilization of the manufacturing plant capital due to intermittent energy delivery . Because of this, manufacturing plants that are less complex and have smaller non-variable operations and capital costs may be more attractive for integration. A secondary economic barrier for the HES is the market availability for its products. The system must operate a region where there is either an intermittent demand for its electricity, an intermittent demand for its secondary product, or both. In a region with an intermittent demand, product prices should shift accordingly, making it less attractive to produce one of the products. The HES then can shift production in order to maximize profit. Without an intermittent demand for at least one of its products, there would be little need for it to expend the extra capital required for integration as an HES.
32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗