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Around the world, efforts are increasing to drastically reduce greenhouse gas (GHG) emissions by 2050. The goal of the Paris Agreement is to hold the increase in global average temperature rise to below 2°C as compared with preindustrial levels, specifically aiming to limit it to 1.5°C. As of 2017, the global average temperature rise reached approximately 1°C. It is expected to hit the 1.5°C mark by 2040 if current trends continue. Limiting temperature rise to 2°C will require reaching net zero emissions in the latter half of the 21st century; GHG emissions would need to reach a near-zero value bymore » 2050 to limit the rise to 1.5°C.« less

Multiple studies suggest that by 2030, millions of jobs may go unfilled because of a significant skills gap between the current manufacturing workforce and the workforce needed to support the shift toward advanced and sustainable manufacturing. According to US manufacturers, finding the right talent is more difficult now than in previous years. Developing a well-trained workforce will play a critical role in transforming the manufacturing sector into a net-zero contributor of greenhouse gas emissions by 2050. To help reduce energy, water, waste, and greenhouse gas emissions as well as build a strong, sustainable manufacturing workforce, the US Department of Energymore » created the voluntary Better Plants program in 2011. This study discusses the program’s various workforce development activities, including in-plant trainings, virtual in-plant trainings, and in-person bootcamps. The target audiences, training objectives, and topics designed to upskill workers for a low-carbon manufacturing future are described. Feedback that was collected (e.g., new training topics, certifications, hands-on activities) while working with more than 270 US manufacturers for the past 12 years on workforce development are discussed. Finally, some strategies are proposed to address the feedback.« less

Rapid decarbonization is fast becoming the primary environmental and sustainability initiative for many economic sectors. Industry consumes more than 30 % of all primary energy in the United States and accounts for nearly 25 % of all greenhouse gas (GHG) emissions. More than 70 % of energy consumed by the industrial sector is related to thermal processes, which are also the largest contributors of carbon emissions, overwhelmingly due to the combustion of fossil fuels. Thermal process intensification (TPI) seeks to dramatically improve the energy performance of thermal systems through technology pillars focusing on alternative energy sources and processes, supplemental technologies,more » and waste heat management. The impacts of TPI have significant overlap with the goals of industrial decarbonization (ID) that seeks to phase out all GHG emissions from industrial activities. Emerging supplemental technologies such as smart manufacturing (SM) and the industrial internet of things (IoT) enable significant opportunities for the optimization of manufacturing processes. Combining strategies for TPI and ID with SM and IoT can open and enhance existing opportunities for saving time and energy via approaches such as tighter control of temperature zones, better adjustment of thermal systems for variations in production levels and feedstock properties, and increased process throughput. Data collected by smart processes will also enable new advanced solutions such as digital twins and machine learning algorithms to further improve thermal system savings. Herein, this paper examines the individual pathways of TPI, ID, and SM and how the combination of all three can accelerate energy and GHG reductions.« less

Manufacturing, in the effort to be more sustainable, is increasingly focusing on energy efficiency and waste reduction. DOE’s Better Buildings Better Plants Program has a Waste Reduction Network that works with 32 industrial partners to achieve higher material efficiency and reduce waste. United States generates 7.6 Billion Tons of industrial solid waste as estimated by EPA. In a linear economy as the economy grows, so does the waste – increasing strain on resources and the environment. The Circular Economy (CE) model keeps the available resources in circulation for longer period of time easing the burden on the environment. Remanufacturing andmore » (Beneficial) re-use are widely accepted channels in 9R methodology and established pillars of CE. This paper reviews the two key strategies and their adoption in different industrial sectors. It reviews the key barriers faced by manufacturers in implementing these methodologies and discusses the possible solutions to those barriers. The paper also reviews impact of these CE strategies on sustainability, material efficiency and the economic and social benefits. Finally, this paper presents two case studies from DOE’s Better Plants partners – one on remanufacturing of components in heavy vehicles industry and one on beneficial reuse of spent foundry sand, a non-hazardous solid waste, and discusses the project impacts.« less

The Framework for Greenhouse Gas Emissions Reduction Planning: Industrial Portfolios articulates a process to help industrial organizations develop a specific, actionable plan to achieve Scope 1 and Scope 2 greenhouse gas (GHG) emissions reduction – an Emissions Reduction Plan (ERP). An ERP covers an entire portfolio of facilities, yet contains enough detail to be practically useful at the facility level.

The purpose of this paper is to review existing smart manufacturing (SM) maturity models' dimensions and maturity levels to assess their applicability and drawbacks. There are many maturity models available but many of them have not been validated or do not provide a useful guide or tool for applications. This gap creates the need for a review of the existing maturity model's applicability. Nineteen peer-reviewed maturity models related to “Digital Transformation,” “Industry 4.0” or “Smart Manufacturing” were selected based on a systematic literature review and five consulting firm models were selected based on the author's industry knowledge. The chosen modelsmore » were analyzed to determine 10 categories of dimensions. Then they are assessed on a 1–5 scale for how applicable they are in the 10 categories of dimensions. The five “consulting firm” models have a first-mover advantage, are more widely used in industry and are more applicable, but some require payment, and they lack published details and validation. The 19 “peer reviewed” models are not as widely used, lack awareness in the industry and are not as easy to apply because of no web tool for self-assessment, but they are improving. The categories defined to characterize the models and facilitate comparisons for users include “Information Technology (IT) and Cyber-Physical System (CPS) and Data,” “Strategy and Organization,” “Supply Chain and Logistics,” “Products and Services,” “Culture and Employees,” “Technology and Capabilities,” “Customer and Market,” “Cybersecurity and Risk,” “Leadership and Management” and “Governance and Compliance.” The analyzed maturity models were particularly weak in the areas of cybersecurity, leadership and governance. Researchers and practitioners can use this review with consideration of their specific needs to determine if a maturity model is applicable or if a new model needs to be developed. The review can also aid in the development of maturity models through the discussion of each of the dimension categories. Finally, compared to existing reviews of SM maturity models, this research determines comprehensive dimension categories and focuses on applicability and drawbacks.« less

Abstract Reducing food loss and waste can improve the efficiency of food supply chains and provide food security. Here we estimate mass flow as well as food loss and waste along the US food supply chain for 10 commodity groups and nine management pathways to provide a baseline for designing efficient strategies to reduce, recycle, and recover food loss and waste. We estimate a total food loss and waste of 335.4 million metric tonnes from the U.S. food supply chain in 2016. Water evaporation (19%), recycling (55%), and landfill, incineration, or wastewater treatment (23%) accounted for most of the lossmore » and waste. The consumption stage accounted for 57% of the food loss and waste disposed of through landfill, incineration, or wastewater treatment. Manufacturing was the largest contributor to food loss and waste (61%) but had a high recycling rate. High demand, perishable products accounted for 67% of food waste. We suggest that funding for infrastructure and incentives for earlier food donation can promote efficiency and sustainability of the supply chain, promote FLW collection and recycling along the U.S. FSC, and improve consumer education in order to move towards a circular economy.« less

Manufacturing facilities use about 35% of the domestic energy in the United States every year. Implementing an effective energy management system (EnMS) is one of the most important approaches to improve energy efficiency. However, the implementation of EnMS is low for many countries (including the US) and even for energy-intensive sectors. The reasons for the low implementation rate of energy management systems had been investigated by multiple researchers, but very few studies have focused on the barriers and challenges of implementing ISO 50001-based energy management systems. To contribute to this understudied area, this paper discusses the implementation and outcomes ofmore » the first Better Plants 50001 Ready Virtual In-plant Training. This paper first provides an overview of 50001 Ready and the 50001 Ready Navigator Tool. Then, it provides details on this training event and its outcomes. Finally, it discusses findings from the responses to 40 live polling questions about the status of the 25 tasks of the 50001 Ready Navigator for participating companies, key components of the participating manufacturing companies’ energy management systems, and challenges and barriers that these companies are facing. The findings suggest that although many companies understood the importance of an effective energy management system, about half of them do not understand the required resources for building energy management systems, and most of them have only just begun establishing these systems and need more assistance and resources in multiple areas. More specifically, more assistance is necessary for the following: (1) improving corporate management’s understanding of the time and resources needed to build an EnMS as well as the benefits; (2) creating linear regression models for more accurate energy performance tracking; (3) understanding energy use, collecting and analyzing energy performance data; (4) optimizing equipment operational controls, and creating action plans.« less

The US Department of Energy’s (DOE’s) Advanced Manufacturing Office held the virtual workshop entitled “Thermal Process Intensification: Transforming the Way Industry Uses Thermal Process Energy” in November and December 2020. The workshop brought together participants from universities/laboratories, industries, equipment manufacturers, technology vendors, nongovernmental organizations, and subject-matter experts to discuss transformative technologies and strategies to substantially improve the performance (e.g., energy productivity, thermal efficiency, reduced greenhouse gas [GHG] emissions, reduced number of process steps) of thermal processing systems in the industrial sector. The US industrial sector accounts for 32% of the nation’s primary energy use (including feedstocks), and refining, chemicals, pulpmore » and paper, iron and steel, and food products represent the top energy-consuming sectors. Thermal processing or process heating represents the largest energy use category; it accounts for 63% of all energy use in manufacturing. Additionally, thermal processing is the largest contributor of carbon dioxide (CO2) generation, resulting from combustion of fuels and process related chemical reactions, such as in the case of cement and lime production. The challenge of achieving net-zero industrial GHG emissions is colossal considering the established industrial base that depends mainly on carbon-based processes and energy sources; the time frame and cost to replace carbon-based energy sources and feedstocks; and the long-term outlook for development with large-scale adaptation of alternative non carbon–based technologies. The goals of the DOE Advanced Manufacturing Office Thermal Process Intensification Workshop were as follows: (1) Identify R&D gaps and opportunities to facilitate transformative improvement in industrial thermal processes beyond current technologies and allow for entirely new methods for processing materials; (2) Gain insight into new and innovative approaches to thermally intensify processes, reduce heat demand, harness waste heat, and use fuels and hydrocarbon feedstocks more efficiently; (3) Identify the R&D pathways to thermal process intensification (TPI) with the highest potential for impact and adoption by the industrial sector; (4) Define areas of research, development, and demonstration (RD&D) activities to accelerate development and application of emerging and transformative technologies to intensify thermal processes in industry. The scope and focus of the workshop were defined to meet these goals. Based on the available data for energy use and GHG emissions, the industries that collectively use more than 80% of the total process heating energy consumption were selected as primary focus areas. The chosen industries were combined into the following four groups based on similarities in their thermal processes: high-temperature metal processing (iron and steel industry, alumina-aluminum industry); high-temperature nonmetal and mineral processing (cement and glass industry); medium- to low-temperature thermal processing (food processing and pulp and paper industry as part of forest products sector); and hydrocarbon processing (petroleum refining and chemical industry). Furthermore, all potential TPI technologies associated with the processes defined were considered as part of the workshop. Different types of TPI technologies possible in industrial in the document.« less

Geothermal reservoir characterization, construction, and operations are technology-intensive activities that contribute significantly to the cost of delivering renewable electricity. The technologies involved, such as downhole tools and drilling equipment, are similar to those used in oil and gas exploration and production must often be adapted for use in the corrosive, high-temperature geothermal reservoir environment. Low production volume of geothermal tools presents a major challenge in meeting the industry's technology needs. Production of specialized tools for geothermal subsurface applications is often cost-prohibitive. Reduced inventory of subsurface well construction, characterization, and production tools causes geothermal reservoir development efficiency and sophistication to lagmore » behind that of the oil and gas industry. Advances in additive manufacturing provide opportunities to advance geothermal technology while reducing lead time and costs associated with production of low-volume, complex parts. Additionally, this paper performs an initial techno-economic analysis comparing the cost of conventional production techniques and additive manufacturing for geothermal downhole applications. An analysis of representative downhole tools is used to create a framework for estimating fabrication costs of subtractive and additive techniques, including post-print machining required to meet final tolerances. The framework is used to explore several manufacturing scenarios and identify the dominant factors driving manufacturing time and cost. The current feasibility of additive manufacturing for geothermal downhole tool applications is assessed and issues for future development to better meet the needs of the geothermal industry are identified.« less