Techno-Economic Analysis of Hybrid Layered Manufacturing

Subtractive manufacturing (CNC machining) has high quality of geometric and material properties but is slow, costly and infeasible in some cases; additive manufacturing (RP) is just the opposite. Total automation and hence speed is achieved in RP by compromising on quality. Hybrid Layered Manufacturing (HLM) developed at IIT Bombay combines the best features of both these approaches. It uses arc welding for building near-net shapes which are finish machined to final dimensions. High speed of HLM surpasses all other processes for tool making by eliminating NC programming and rough machining. The techno-economic viability of HLM process has been proved through a real life case study. Time and cost of tool making using HLM promises to be substantially lower than that of CNC machining and other RP methods. Interestingly, the material cost in HLM was also found to be lower. HLM is a cheaper retrofitment to any 3 or 5 axis CNC milling machine or machining center.Mechanical Engineerin

A multi-layered view of chemical and biochemical engineering

The contents of this article are based on the results of discussions the corresponding author has had since 2015 with the co-authors, who are members of academia and industry in Europe, on the scope and significance of chemical and biochemical engineering as a discipline. The result is a multi-layered view of chemical and biochemical engineering where the inner-layer deals with the fundamental principles and their application; the middle-layer deals with consolidation and expansion of the principles through a combination of science and engineering, leading to the development of sustainable technologies; and the outer-layer deals with integration of knowledge and collaboration with other disciplines to achieve a more sustainable society. Through this multi-layered view several important issues with respect to education, research and practice are highlighted together with current and future challenges and opportunities

Futures of shipbuilding in the 22nd century : Explorative industry foresight research of the long-range futures for commercial ship-building, using elements of OpenAI.

The shipbuilding industry has historically shaped global trade, logistics, research, and cultural globalization. It was instrumental in exploring and colonizing new continents, thereby significantly shaping our society. Today, it's essential to consider the industry's current transformations and speculate on what shipbuilding might look like in the 22nd century. This study is dedicated to exploring the possible futures of shipbuilding over a long-range time horizon of 70 -100 years. This thesis applied futures research methods to data collected using OpenAI tools and explored possible transformative pathways within the industry. The research offers potential future scenarios and delineates change pathways from external pressures and internal shifts within the shipbuilding system. Additionally, the study highlights the possible applications and implications of utilizing OpenAI technology in a research context. The analysis of shipbuilding incorporates the Multi-Level Perspective (MLP) concept, viewing the industry as a system involving ten groups of key actors. This structure guided the data collection process for the input of the research. The primary research process adheres to traditional futures research methods, which include horizon scanning, systems thinking, scenario building, and causal layered analysis (CLA). Furthermore, the methodology was expanded to incorporate AI-assisted techniques. This includes using AI technology for automated data collection and a separate pathway using ChatGPT-4 for computer-generated scenarios and CLA narratives development. The outcomes from both methodologies are compared, and additional literature research about the applicability and implications of using AI in futures studies. The research has identified critical external drivers of change, originating from fields such as technology, energy, and social development, as well as internal drivers, including biotechnology and diversifying floating structures. The external drivers could influence the future direction of shipbuilding, while the internal factors represent potential changes originating from within the industry. The constructed scenarios are designed to stimulate discussion and provide context for future developmental trajectories of shipbuilding

Techno-economic analysis of production of octane booster components derived from lignin

In this study, a comprehensive process for production of an environmentally friendly octane booster (acetophenone) from lignin is presented, along with a detailed techno-economic analysis. Recognizing that much of the prior research on octane boosters has been confined to experimental lab-level investigations, this study develops comprehensive process design to unravel the intricacies of large-scale acetophenone production. The acetophenone production process involves catalytic hydrogenolysis, which also yields phenol as a valuable side product. Based on the process flow diagram, mass and energy balances were developed, revealing significantly improved yields and purity of acetophenone compared to industry standards, reaching 0.74 kg acetophenone per kg of lignin and 99 wt%. In the techno-economic analysis, calculations involving fixed capital investment (FCI), operating costs, and working capital were conducted based on a feed of 100 kg/h of dry lignin. The results indicate FCI at 2.72 million USD, operating costs at 1.09 million USD per year, and working capital at 0.57 million USD. Assuming a 20-year operational lifespan, the payback period is estimated at 6.09 years, as depicted by the cumulative cash flow diagram. Moreover, techno-economic analysis demonstrates a net present value (NPV) of 3.24 million USD at a 10% discount rate, an internal rate of return (IRR) of 22.73%, and a return on investment (ROI) of 34.39%. These positive outcomes underscore the robust profitability of the proposed acetophenone production plant derived from lignin. Additionally, a sensitivity analysis on the IRR indicates that increasing the production capacity could further enhance profitability, reaffirming the feasibility of the plant’s operation. Crucially, this study highlights the potential for sustainable and economically viable production of acetophenone, offering an environmentally friendly alternative to toxic octane boosters and advancing the development of sustainable fuel additives. Graphical Abstract: [Figure not available: see fulltext.

An overview of research programmes and prospective technology in the development of more secure supply chains: The Case of Shipping Containers

The development of new, more secure, container systems should consider the main techno-economic items and devise a solution that, not only provides increased tamper-resistance, but also contains economically beneficial buy-in features that will motivate the adoption of new container models by the shipping trade. This report provides an overview of these aspects within the context of EU policy and R&D programmes in this area.JRC.G.5-European laboratory for structural assessmen

A critical review: recent developments of natural fiber/rubber reinforced polymer composites

Recent advancements in the development of low-emission materials have become a global imperative to achieve net-zero emissions in efforts to limit the effects of climate change. The materials transition agenda not only aims to substitute emission-intensive materials but also incorporates emission reduction efforts into goods and applications. Natural fiber composites have received attention from both commercial and research communities because of their inherent eco-friendliness, lower cost, and lower energy consumption during processing than their synthetic counterparts. Additionally, rubber-reinforced polymer composites have generally shown promising results, particularly in resisting sudden deformation. Although studies combining waste rubber with natural fibers in polymer composites are nascent, with limited existing literature, this area demonstrates remarkable potential for the substitution of traditional synthetic composites. Therefore, this review outlines the recent developments in polymer composites incorporating the use of natural fibers and rubber in various forms. The use of rubber as a filler has been shown to enhance tensile strength and impact performance while enhancing the surface finish, however, conflicting studies were identified. Hybridizing waste rubber and natural fibers presents a promising path to further enhance the mechanical performance of composite materials. Emphasis has been placed on the use of fillers in various forms and on their inclusion in thermoset matrices. The future outlook and research opportunities are also presented in this review.</p

The most effective techniques of industrial purification processes: a technical review

This paper reviews various separation techniques used in purification processes to remove pollutants like carbon dioxide and hydrogen sulfide from petroleum products. The most effective techniques include absorption, adsorption, cryogenic distillation, chemical looping combustion, and membrane separation. The study reviews over 100 published studies to assess their characteristics, benefits, and drawbacks. The choice of separation technology depends on ideal conditions, cost, efficiency, and energy required in the regeneration phase

2023 roadmap for potassium-ion batteries

The heavy reliance of lithium-ion batteries (LIBs) has caused rising concerns on the sustainability of lithium and transition metal and the ethic issue around mining practice. Developing alternative energy storage technologies beyond lithium has become a prominent slice of global energy research portfolio. The alternative technologies play a vital role in shaping the future landscape of energy storage, from electrified mobility to the efficient utilization of renewable energies and further to large-scale stationary energy storage. Potassium-ion batteries (PIBs) are a promising alternative given its chemical and economic benefits, making a strong competitor to LIBs and sodium-ion batteries for different applications. However, many are unknown regarding potassium storage processes in materials and how it differs from lithium and sodium and understanding of solid–liquid interfacial chemistry is massively insufficient in PIBs. Therefore, there remain outstanding issues to advance the commercial prospects of the PIB technology. This Roadmap highlights the up-to-date scientific and technological advances and the insights into solving challenging issues to accelerate the development of PIBs. We hope this Roadmap aids the wider PIB research community and provides a cross-referencing to other beyond lithium energy storage technologies in the fast-pacing research landscape

Roles of Exogenous Technologies in Vehicle Innovation: Cases from a Japan’s Automotive Parts Manufacturing Firm

This paper explores the roles of technological innovations in the growth of Japan’s motor vehicle industry, mainly from technology spillover perspective from the early 2000s to today. An empirical analysis focusing on business performances, R&amp;D investments, and patent applications taking a noteworthy unique case in Japan was attempted. Empirical analyses on the productivity of patent to technology stock, use of exogenous technologies for their own technological innovation on its Automotive Business Unit elucidated that innovation capabilities, incorporation of exogenous technologies, and profit generation makes a virtuous cycle of continuous technological innovation. Furthermore, we found that the range of technology spillovers is not only expanding along with the development of information communication technology but also superposing itself intricately between organizational (industry– firm–business unit) layers

Cool White Polymer Coatings based on Glass Bubbles for Buildings.

While most selective emitter materials are inadequate or inappropriate for building applications, here we present a techno-economically viable optical coating by integrating glass bubbles within a polymer film. A controlled glass bubble volume concentration from 0 to 70% leads to a selective solar reflectivity increase from 0.06 to 0.92 while the mid-infrared emissivity remains above 0.85. Outdoor measurements show the polymer coating on a concrete surface can provide a temperature reduction up to 25 °C during the day when conduction and convection are limited and a net cooling power greater than 78 W/m2 at a cost less than $0.005/W. The impact of polymer coating on common buildings is estimated as potential annual energy savings of 2-12 MJ/m2 and CO2 emission savings of 0.3-1.5 kg/m2. More savings are expected for higher surface-area-to-volume-ratio buildings, and the polymer coating is also expected to resolve cooling issues for old buildings with no air conditioning