Mehnuma Tabassum, Riad Ramadani, Elif Elçin Günay, Gül E. Kremer
{"title":"Effects of Material Selection on the Remanufacturability of a Swashplate in an Axial Piston Pump","authors":"Mehnuma Tabassum, Riad Ramadani, Elif Elçin Günay, Gül E. Kremer","doi":"10.1002/amp2.70027","DOIUrl":"https://doi.org/10.1002/amp2.70027","url":null,"abstract":"<p>A swashplate is a critical component in an axial piston pump for motion transformation that undergoes cyclic loading. Traditionally, swashplates are not designed to have multiple lives of operation. According to industry experts, a remanufacturability analysis of swashplates suggests that the scrap rate is high. Among the primary reasons for this high scrap rate is insufficient material on the running surface, especially for subtractive recovery. Therefore, the selection of the proper material and its amount plays a significant role in the fatigue behavior, the remanufacturability of the swashplate, as well as its cost. Analyses addressing fatigue life, remanufacturability, and cost of the swashplate were carried out in this paper through a comparative study utilizing various materials. Recommendations on the material selection that balance the failure consequences, remanufacturability, and cost are provided to guide designers in making informed decisions for alternative design options.</p>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-07-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70027","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716517","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Proposal for a Circular Recycling of Hydrocarbon Plastics","authors":"Swaminathan Ramesh, Haz Patel","doi":"10.1002/amp2.70021","DOIUrl":"https://doi.org/10.1002/amp2.70021","url":null,"abstract":"<div>\u0000 \u0000 <p>Over 430 million tons of plastic were produced in the year 2022, and 2/3rd of them were of short-term use. Besides good successes in recycling PET (No 1) and HDPE (No 2), most of them end up in landfills or waterways and oceans. Even recycling of plastic by mixing them with virgin plastic has problems, as they contain large amounts of pharmaceuticals and other undesirable chemicals. One of the desirable ways to chemically recycle a plastic is to take it back to its starting monomers, which can then be re-polymerized into virgin plastic—a circular recycling. A polyester (PET) polymer can be hydrolyzed back to diacids and diols, and after cleaning, polymerized back to PET with the same characteristics as the original polymer. There are catalytic pyrolytic ways to produce naphtha (C<sub>4</sub>–C<sub>7</sub>) that can be a starting material for ethylene and propylene to be repolymerized to PE and PP. Inductively coupled depolymerization of plastic can, under the right conditions (Eco Fuel Technology, US Patent 9 505 901), take the polymer all the way to its monomer (85–90 + % yield). Mixtures of plastic can be reacted, and the resulting ethylene, propylene, or styrene can be separated to get pure monomers that can be re-polymerized. This will be a true circular chemical recycling and this paper will propose ways to scale up the process to industrial scale. This cycle can be repeated indefinitely and the process by itself does not add any CO<sub>2</sub>.</p>\u0000 </div>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70021","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716531","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Abu Islam, Matthew DeHaven, Marshall Neipert, Nenad Nenadic
{"title":"Automation for Electric Vehicle Battery Pack Disassembly","authors":"Abu Islam, Matthew DeHaven, Marshall Neipert, Nenad Nenadic","doi":"10.1002/amp2.70025","DOIUrl":"https://doi.org/10.1002/amp2.70025","url":null,"abstract":"<div>\u0000 \u0000 <p>Battery-electric vehicles (EVs) are growing exponentially. The demand for these batteries is expected to increase sevenfold by 2035. The EV batteries reach their end of life when the capacity fades to 70%–80% of new, with some being removed from the primary applications with even lower levels of degradation. These batteries can be used in less demanding applications. The disassembly process is currently manual, slow, unsafe, and expensive. Automation is needed to increase the throughput. EV battery packs feature various continually changing designs and form factors, which limit the usefulness of deterministically programmed robotic solutions. The conceptual robotic disassembly of EV batteries has attracted the attention of researchers. However, while many approaches have been proposed, practical implementations are lacking. We review proposed concepts for EV battery disassembly and describe the selected approach, with elements of partial solutions validated in a laboratory setting, including the selection of commercial solutions, the development of custom end effectors, and methodologies for detection, localization, and classification of fasteners. The computer vision tasks employed an overhead 2D camera to detect the type of battery pack and approximate localization of fasteners, and a 3D camera mounted on the robotic arm for precise localization (position and tilt) and classification.</p>\u0000 </div>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-06-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70025","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716723","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Hazim F. Abbas, Wameath Sh. Abdul-Majeed, Zahra Rabia Al-Riyami, Sara Nasser Al-Habsi
{"title":"Application of Multi Flying Jet Plasma Torches Reactor for Hydrogen Production via Methane Decomposition: Optimization Study","authors":"Hazim F. Abbas, Wameath Sh. Abdul-Majeed, Zahra Rabia Al-Riyami, Sara Nasser Al-Habsi","doi":"10.1002/amp2.70026","DOIUrl":"https://doi.org/10.1002/amp2.70026","url":null,"abstract":"<div>\u0000 \u0000 <p>The emission of methane and carbon dioxide from greenhouse gases and vehicle emissions is a major contributor to air pollution. This research is aimed to convert methane into hydrogen gas through using non-thermal plasma decomposition. Twenty experiments were conducted, and three parameters were manipulated: voltage of the plasma power source, methane gas flow rate and argon gas flow rate which is streamlined to operate the plasma reactor. The best result was found in the experiment at 3 kV, 8 L/min of argon gas, and 75 mL/min of methane gas, producing 635 ppm of hydrogen gas. The study outcomes were incorporated in a model which highlighted the relationship between the power source voltage, flow rate of argon and methane as a function of the hydrogen produced. Additionally, the results disclosed that other gases, such as carbon dioxide, ethylene, and ethane, were also produced during the decomposition process. The results of this research demonstrate the potential of a novel Multi Flying Jet Plasma Torches reactor for efficient, eco-friendly hydrogen production through methane decomposition, offering optimized operational parameters and predictive modeling that enhance process scalability and reduce environmental impact compared to conventional methods.</p>\u0000 </div>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70026","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716834","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Innovative Sorting for Sustainable Futures: Fiber Identification Technologies Tested in California to Drive Textile Circularity","authors":"Joanne Brasch, May Myo Myint, Yalin Li","doi":"10.1002/amp2.70024","DOIUrl":"https://doi.org/10.1002/amp2.70024","url":null,"abstract":"<div>\u0000 \u0000 <p>Textiles is a growing waste stream ripe with opportunities for better materials management and promotion of businesses aligned with textile reuse and repair. The California Product Stewardship Council (CPSC) is leading textile policy development and textile recovery projects focused on expanding circular fiber systems with reduced cost burden on local government and taxpayers through extended producer engagement. Innovative fiber identification and pre-processing solutions are needed to enhance the efficiency and efficacy of Materials Recovery Facilities. Various textile scanning technologies are available on the market, with Near-Infrared Spectroscopy (NIR) emerging as the most promising and market-ready option due to its wide use in solid waste and recycling contexts. The article compares multiple NIR-based fiber identification devices tested in CPSC's recent pilot projects to provide a comprehensive overview of the current market landscape. The article discusses the potentials of handheld and tabletop devices in comparison to large-capacity machines, and challenges for accurate fiber identification due to the diverse nature of textile waste, including complex fabric blends, multi-layers, and the presence of disruptors such as prints, embroidery, and zippers. Industry-wide collaboration and the establishment of regulations and standards are required to overcome the current technical and economic challenges in textile circularity. The article will present recommendations for data collection, transparency, and accountability in the industry, and will discuss the role of policy development in creating economic incentives such as financial support, tax incentives, or subsidies for MRFs investing in state-of-the-art scanning solutions to expedite the transition toward more sustainable and efficient circular economy practices.</p>\u0000 </div>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70024","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716833","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Zhuo Xu, Fei Long, Zach Wagner, Charles Granger, Euncheol Ra, Shiying Cai, George W. Huber, Ezra Bar-Ziv
{"title":"Extraction of Pure Plastic Resins From PCR Plastic Waste by Solvent-Targeted Recovery and Precipitation (STRAP)","authors":"Zhuo Xu, Fei Long, Zach Wagner, Charles Granger, Euncheol Ra, Shiying Cai, George W. Huber, Ezra Bar-Ziv","doi":"10.1002/amp2.70023","DOIUrl":"https://doi.org/10.1002/amp2.70023","url":null,"abstract":"<div>\u0000 \u0000 <p>We have been developing a solvent-based plastic recycling technology called STRAP. The technology is based on dissolving a targeted plastic resin in a specific solvent that does not dissolve other resins. We have demonstrated STRAP in thousands of bench scale experiments for a large variety of wastes. Recently we have demonstrated the technology for PCR, using mixed plastic wastes (MPWs), from a wet Material Recovery Facility (MRF). The process includes (1) infrared (IR) characterization to determine the plastic composition for accurate selection of the solvent to be used for the extraction of the pure resins. (2) Shredding to the right size and aspect ratio required for flowable and fast dissolvable process. (3) Mixing the MPW in the first solvent to dissolve the first resin. (4) Filtration of the solution plastic blend, to separate the nondissolved plastic from the solution. (5) Further filtration of the solution to remove micron-sized particle of pigments and fibers. (6) Cooling for precipitation. (7) Filtration of pure resins. (8) Drying of a pure resin. (9) Extrusion of the resin to pellets. (10) Generating films or other products from the pure resin. Steps 1–10 can be considered as one-cycle that extracted the first resin. (11) A second resin can be extracted with a respective solvent from the plastic that did not dissolve in the first cycle and following steps 1–10 described above. The process also includes characterization of interim and final products. The effort includes building a pilot system at 25 kg/h throughput. We will present specific results for various PCR.</p>\u0000 </div>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-06-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70023","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716832","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Emmanuel Akubueze, Atul Kumar Maurya, Patrick Masembe, Niyi G. Olaiya, Nicholas Bowen, Davide Masato, Margaret J. Sobkowicz, Amir Ameli
{"title":"Polypropylene Composites Reinforced With Recycled Waste Cellulosic Fiber/Fine Mixture: The Impact of Cellulose Sieving on Performance","authors":"Emmanuel Akubueze, Atul Kumar Maurya, Patrick Masembe, Niyi G. Olaiya, Nicholas Bowen, Davide Masato, Margaret J. Sobkowicz, Amir Ameli","doi":"10.1002/amp2.70022","DOIUrl":"https://doi.org/10.1002/amp2.70022","url":null,"abstract":"<p>This study explores how a sieving step of waste cellulosic fiber and fine (WCFF) mixture affects the performance of WCFF-loaded polypropylene (PP) composites and whether the separation of fines from fibers offers an added benefit. The WCFF samples were downsized, and four different filler size ranges were sieved using a series of mesh sizes from 4 to 0.85 mm. The WCFF/PP composites were then compounded at 20 wt.% loading of WCFF using a twin-screw extruder. Incorporating WCFF increased the tensile strength to 41.28 MPa and the modulus to 3207 MPa, accounting for 28% and 38% enhancements, respectively. Interestingly, the greatest improvements were associated with the nonsieved WCFF case, and the sieved WCFF fibers provided only marginal enhancements over virgin PP. The outperformance of nonsieved WCFF was attributed to the synergistic reinforcement of hybrid fibers and fines as well as the maintenance of longer fibers in the system. However, the strain at break and impact strength of PP decreased after introducing WCFF. Moreover, the complex viscosity and storage modulus increased with an increase in the filler size, due to the formation of a more effective percolative network. The PP's crystallinity exhibited a relatively strong dependency on the sieving, where WCFF samples with short-aspect-ratio fillers promoted the crystallinity significantly. It was also found that the WCFF degradation onset temperature increased once it was incorporated into PP. This study suggests that waste cellulosic feedstocks can be utilized as a reinforcement without additional sieving to manufacture high-performance and cost-effective composites.</p>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-06-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70022","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716712","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Naveen Kumar Muthumanickam, Swaroop Atnoorkar, Heather Goetsch, Michael Deru, Jordan Palmeri, Milad Ashtiani, Vaclav Hasik, Mirko Farnetani
{"title":"BRE-X Emissions Database for End-of-Life Scenarios of Selective Building Construction Materials to Enable Circular Economy in Construction","authors":"Naveen Kumar Muthumanickam, Swaroop Atnoorkar, Heather Goetsch, Michael Deru, Jordan Palmeri, Milad Ashtiani, Vaclav Hasik, Mirko Farnetani","doi":"10.1002/amp2.70018","DOIUrl":"https://doi.org/10.1002/amp2.70018","url":null,"abstract":"<p>In the United States, construction and demolition debris predominately end up in landfills with minimal end-of-life Re-X (recover, recycle, reuse, etc.) scenarios, resulting in large environmental impacts and lost opportunities for material recovery. Except for concrete and metals, which seem to have a few well-defined end-of-life pathways, there seems to be a lack of well-documented end-of-life scenarios for other construction materials, let alone their emissions data. Hence, there is a need for documented end-of-life Re-X scenarios and end-of-life data of more building materials to motivate widespread use of Re-X strategies in building design. This paper outlines the efforts of the National Renewable Energy Laboratory, Carbon Leadership Forum, Building Transparency, and Skidmore, Owings & Merrill to (a) create an open-access BRE-X (Building Re-X) end-of-life emissions database consisting of greenhouse gas emissions data associated with various end-of-life scenarios for a select list of high-impact building construction materials, and (b) integrate the BRE-X end-of-life emissions database with CAD/BIM/LCA tools for evaluating various end-of-life scenarios. The paper also presents a few existing life cycle inventory databases that contain sparse amounts of end-of-life data for a few construction materials and their limitations in terms of scaling and data consolidation. Finally, a sample of how the collected data can be ingested into whole-building LCA tools using open data formats and a public access link to the BRE-X end-of-life emissions database is also included.</p>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-06-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70018","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716487","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Techno-Economic Analysis of Polypropylene Recycling Through Catalytic Pyrolysis: FCC Catalysts in Batch Reactors","authors":"Farhad Zaker Hosseiny, Rui Shi","doi":"10.1002/amp2.70016","DOIUrl":"https://doi.org/10.1002/amp2.70016","url":null,"abstract":"<p>The short lifespan of plastics, particularly in the packaging sector, results in rapid accumulation of plastic waste, with polypropylene being a major contributor. Chemical recycling is gaining increasing attention as a strategy in managing plastic waste, facilitating the transition from a linear to a circular economy. This study presents a comprehensive techno-economic analysis (TEA) of a polypropylene recycling process via pyrolysis designed for a facility in the Southern United States, processing 300 kt of waste annually. The process was modeled using Aspen Plus for energy and mass balance and Aspen Process Economic Analyzer for capital cost estimations, with additional manual calculations for operating costs. Economic viability was assessed through net present value (NPV), internal rate of return (IRR), and Minimum Fuel Selling Price (MFSP). Results show that recycling polypropylene via catalytic pyrolysis is economically viable, with a NPV exceeding $330 million and an IRR of 29.6% over a 30-year lifespan. The base case (300 kt/year) demonstrates the most promising financial viability, with high IRR and favorable ROI. Sensitivity analysis highlights the impact of market factors and operational costs on the economic viability of the process. Equipment cost breakdown shows that the “Storage” area, particularly the costs associated with hydrogen storage, is a significant contributor to the total capital investment. This finding highlights the importance of on-site hydrogen production to further reduce capital investments and operational costs.</p>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-06-13","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70016","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716736","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"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","authors":"Greg Avery, Alberta Carpenter","doi":"10.1002/amp2.70012","DOIUrl":"https://doi.org/10.1002/amp2.70012","url":null,"abstract":"<p>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.</p>","PeriodicalId":87290,"journal":{"name":"Journal of advanced manufacturing and processing","volume":"7 3","pages":""},"PeriodicalIF":0.0,"publicationDate":"2025-06-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://onlinelibrary.wiley.com/doi/epdf/10.1002/amp2.70012","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144716701","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}