Resource-efficient Production Research Articles

Natural resources, trade and fintech in the era of digitalization: A study of economies involved in Belt and Road Initiative

The present study aims to elucidate the impact of digitalization, fintech, trade, and industrial growth on natural resource consumption in emerging economies within the Belt and Road Initiative (BRI) countries. Employing the Cross-sectional Augmented Autoregressive Distributed Lag (CS-ARDL) method to mitigate Cross-sectional Dependence (CD) and heterogeneity in slope parameters across panels, this study investigates the previously mentioned relationship. Meticulously selecting panel data from twenty-four emerging countries spanning from 1995 to 2021 in the BRI region, the study offers a robust analysis. The findings of this study reveal the positive impact of digitalization on natural resources, as the proliferation of digital devices, data centers, and internet connectivity contributes to higher energy demands, surging the use of natural resources like fossil fuels and electricity. However, the negative impact of fintech on natural resource consumption shows the adoption of energy-efficient technologies, implementation of e-waste management policies, and advocacy for renewable energy addition in energy system. The result shows trade can reduce pressure on natural resources and endorses that BRI can improve trade activities in the member countries, however, actions such as emphasizing green technology adoption, allocating funds for conservation, promoting sustainable resource management, and investing in resource-efficient production, may contribute positively to preserving natural resources in the member nations. Thus comprehensive approach encompassing trade, industrial growth, and the promotion of financial technologies, collectively could strengthen sustainable resource management efforts in the BRI economies.

Optimizing energy modeling in PBF-LB/M metal additive manufacturing: a detailed analysis of resource and energy demand based on standard tensile test specimen

AbstractAdditive manufacturing is an essential tool in modern production processes. Competitive quality and the increasing importance of local manufacturing have allowed companies to maintain their production despite supply chains disrupted by the pandemic. However, the rising awareness of society towards environmental and climate protection, the increasing demand for resource-efficient products, and recent developments in energy costs are leading to a rethink in manufacturing processes. Additive manufacturing offers great potential for resource saving components. This study uses standard tensile test specimens to analyze AM processes regarding energy and material flows. The results show a high dependence of energy demand on process time and are transformed into a data-based energy model. Compared to previous energy models, the accuracy can be significantly improved using model data in combination with specific and system-oriented approaches. In addition to system-related saving potentials, design-related optimization potentials can be identified. Innovative and highly resource-saving components can be designed with a design methodology adapted to the extended degrees of freedom of AM. Further saving and recycling potentials can be identified along the material flows. A long-term goal is optimizing and predicting of resource demand in additive manufacturing with a view to the entire product lifecycle.

Proposal of model for prediction of grape processing and spraying time by using IoT smart agriculture sensor data

The grape industry's impact on agriculture and the economy requires precise forecasting for processing and spraying schedules to optimize production. This article introduces an innovative IoT-based model for predicting optimal timings in grape processing and spraying. By integrating real-time environmental and viticultural data, the model improves decision-making, enhancing product quality, reducing energy consumption, and increasing operational efficiency. Crucially, SARIMA predictive algorithms forecast parameters like temperature, humidity, wind speed, and air pressure. This comprehensive model transforms the grape industry, offering advanced decision support and promoting sustainable, resource-efficient production. The research signals a potential shift to precision agriculture, balancing economic viability with environmental stewardship in grapes.

Stresses in repair welding of high-strength steels—part 1: restraint and cold cracking risk

The sustainable and resource-efficient production of wind energy plants requires the use of modern high-strength fine-grain structural steels. This applies to both foundation and erection structures, like mobile or ship cranes. During the assembly of steel structures, unacceptable defects can occasionally be found in the weld area. In most cases, the economical solution would be local thermal gouging of the affected areas and re-welding. Due to the high shrinkage restraint of the joint groove in the overall structure, the superposition of global and local welding-induced stresses may lead to crack formation and component failure, particularly in interaction with the degradation of the microstructure and mechanical properties of high-strength steels during the repair process. However, manufacturers hardly have any information about these issues and there is a lack of recommendations and guidelines to take these safety-relevant aspects into account in adequate repair concepts. The aim of this research is to derive recommendations for repair concepts appropriate to the stresses and materials involved providing a basis for standards and guidelines to avoid cold cracking, damage and expensive reworking especially for high-strength steels. Part 1 of this study involves systematic investigations of influences of shrinkage restraint during repair welding of two high-strength steels S500MLO for offshore application and S960QL for mobile crane structures. The quantification of the shrinkage restraint of repair weld joints was achieved by means of experimental and numerical restraint intensity analysis. In welding experiments with self-restrained slot specimens, restraint intensity and introduction of hydrogen via the welding arc using anti spatter spray were varied systematically to analyse the effect on welding result, residual stresses and cold cracking. It could be shown that increasing restraint intensities result in significantly higher transverse residual stress levels. In the case of hydrogen introduction S500MLO showed no cold cracking independent of the restraint conditions. However, S960QL was found to be considerably cold cracking sensitive if hydrogen is introduced. With increasing restraint intensity length and number of cold cracks increases significantly. Part 2 [1] of this study is focussed on microstructure and residual stresses due to gouging and stress optimization via adequate heat control parameters in repair welding.

Environmental sustainability of Finnish pork production: life cycle assessment of climate change and water scarcity impacts

PurposeThe degrading impacts of livestock production on the environment are well acknowledged. Although ruminants are much studied due to their large contribution to climate change impact, monogastrics are also known to carry a significant load, and mitigation options need investigation. Here, the climate change impact and water scarcity impact of Finnish pork production was investigated using the life cycle assessment approach.MethodsAs the importance of communicating reliable environmental information has been acknowledged in the EU, methods and guidance for this purpose have been developed. Product Environmental Footprint Category Rules have also been published for several food product categories, although not yet for meat. Here, the life cycle assessment methods were used based on PEFCR guidance and the draft version of red meat PEFCR guidance to achieve a reliable, transparent and comparable assessment.ResultsFinnish pork production resulted in a climate change impact of 3.6 kg CO2 eq. kgCW−1 and a water scarcity impact of 0.69 m3 eq. kgCW−1. The largest contribution to the climate change impact came from feed crop production, with an impact of 43%. Land-use changes were included, and their contribution to the Finnish pork climate change impact was 3%. Similarly, in the water scarcity impact, feed crop production was a major contributor, with 41% from fattening pig feed production. Significant contributions to both categories also came from piglet production, including feed crop production, and to the climate change impact from manure storage.ConclusionsFinnish production was seen to already largely utilise sidestreams and domestic feed ingredients, although, e.g. soybean is still used. Based on the results, in mitigating the environmental impacts of Finnish pork production, attention should especially be paid to the resource-efficient production of domestic feed crops and reduced use of organic soils. As current assessment models are unable to grasp the impacts of regenerative farming techniques, the development of LCA methods is also required. Water scarcity impact was seen to be largely affected by the utilisation of feed crops originating from water-scarce countries. As a mitigation measure, the procurement of these feed crops and ingredients should therefore be directed to water-abundant areas and from production which does not depend on irrigation water or the extensive use of synthetic inputs.

A photobioreactor for production of algae biomass from gaseous emissions of an animal house

Sustainable approaches to circular economy in animal agriculture are still poorly developed. Here, we report an approach to reduce gaseous emissions of CO2 and NH3 from animal housing while simultaneously using them to produce value-added biomass. To this end, a cone-shaped, helical photobioreactor was developed that can be integrated into animal housing by being freely suspended, thereby combining a small footprint with a physically robust design. The photobioreactor was coupled with the exhaust air of a chicken house to allow continuous cultivation of a mixed culture of Arthrospira spec. (Spirulina). Continuous quantification of CO2 and NH3 concentration showed that the coupled algae reactor effectively purifies the exhaust air from the chicken house while producing algal biomass. Typical production rates of greater than 0.3 g/l*day dry mass were obtained, and continuous operation was possible for several weeks. Morphological, biochemical, and genomic characterization of Spirulina cultures yielded insights into the dynamics and metabolic processes of the microbial community. We anticipate that further optimization of this approach will provide new opportunities for the generation of value-added products from gaseous CO2 and NH3 waste emissions, linking resource-efficient production of microalgae with simultaneous sequestration of animal emissions.Key points• Coupling a bioreactor with exhaust gases of chicken coop for production of biomass.• Spirulina mixed culture removes CO2 and NH3 from chicken house emissions.• High growth rates and biodiversity adaptation for nitrogen metabolism.Graphical abstractTowards a sustainable circular economy in livestock farming. The functional coupling of a helical tube photobioreactor with exhaust air from a chicken house enabled the efficient cultivation of Spirulina microalgae while simultaneously sequestering the animals’ CO2 and NH3 emissions.

Land Parcel Identification System (LPIS) data allows identification of crop sequence patterns and diversity in organic and conventional farming systems.

Farmers grow crops in specific sequences to lower disease pressure and boost crop productivity, particularly in organic farming where artificial pesticides and chemical fertilisers are prohibited. Knowledge about crop sequences used in organic and conventional farming will aid the development of future farming systems through optimising crop diversity and pre-crop effects for improved resource efficiency. This study aims to investigate crop diversity and patterns in organic and conventional crop sequences in Sweden. Large-scale LPIS field data managed by the European Union (EU) Integrated Administration and Control System (IACS) were used to monitor crop sequences on arable land in Sweden over 10 consecutive years (2005–2014). Individual fields (land parcels) could be followed on 40% of Sweden’s total arable area (349,891 fields extracted) over the 10 years. The LPIS data was combined with information from a database on which fields were farmed organically. Crop distribution, diversity of crop sequences and pre-crops to the main cereal crops (winter wheat, spring barley) were analysed in organic and conventional farming systems in the five agricultural productivity zones of Sweden. The results showed that in the most productive zone in southernmost Sweden, small-grain cereals (particularly winter wheat) were the most common crops (62%), followed by oilseeds (11%), ley and forage crops (9%) and sugar beet (8%), when excluding permanent grassland. In the least productive zone (at higher altitudes and/or latitudes), ley and forage crops dominated (67%), followed by spring cereals (barley, oats) (23%). Crop diversity was higher in the two more productive zones (mean 4.6 crop types) than in two less productive zones (3.4) and organic farms showed 9% higher crop diversity than conventional farms in the most productive zones. Overall, in all zones, the pre-crop to winter wheat was generally a different crop type (3 out of 5 times) e.g., young ley (1–2 years) or grain legume, while the pre-crop to spring barley was most often (4 out of 5 times) another cereal. For both these crops, pre-crop type was more diverse in organic than conventional systems. These findings demonstrate that LPIS data can offer valuable insights into agronomic trends and on-farm practices regarding crop choice and that analysis of field-level LPIS data on crop sequences at large scale can reveal information about organic and conventional cropping in different productivity zones across countries. This information can be used to understand the practical limitations in the use of crop diversity to maximise pre-crop effects. This could in turn support advisory service and policy makers to facilitate more sustainable, productive and resource efficient crop production.

Design guidelines for metal binder jetting

AbstractIn addition to the general advantages of additive manufacturing technologies, such as the resource-efficient production of highly complex components, the metal binder jetting (MBJ) process enables a more cost-effective manufacturing of metal additive components. However, the design freedoms gained by additive manufacturing, and MBJ in particular, are also accompanied by new design restrictions for component design. While a large number of design guidelines are already available for the established additive manufacturing processes, the metal binder jetting process imposes additional requirements on component design, which are currently only inadequately covered in the literature. Therefore, this paper presents the development and derivation of first design rules for the metal binder jetting process using martensitic stainless steel (17–4 PH). In this way, the paper also provides a methodology for deriving guidelines regardless of the material. In total, 13 guidelines have emerged from this, which in part both confirm existing guidelines, but also extend them.

THE POTENTIAL OF REVERSE ENGINEERING AND DIGITAL FABRICATION FOR THE REPAIR OF HIGH-TECH ARCHITECTURE

Abstract. Novel façade constructions and innovative load-bearing structures of the second half of the 20th century pose new challenges for maintenance and repair. The use of advanced technology, especially in High-Tech architecture, calls for the development of specific repair methods adapted to specific building materials and construction techniques. The conservation of these aging facades, often composed of custom-made metal components, requires the production of intricate spare parts to avoid unduly replacements. Digital fabrication presents a possible solution as it allows for the resource-efficient production of complex and non-planar geometries in small numbers while remaining cost-effective. The paper explores the use of photogrammetry and laser scanning to reverse engineer spare parts, as original plans are often missing or incomplete. A complete workflow for the fabrication of bespoke metal components is described using two examples of Swiss High-Tech architecture featuring challenging structural nodes and planar aluminum panels. Finally, the feasibility of remanufacturing spare parts is demonstrated with 3d-printed models.

FUNCTION INTEGRATION IN ADDITIVE MANUFACTURING: A REVIEW OF APPROACHES

AbstractThis paper provides an overview of established approaches for function integration in additive manufacturing and critically compares their capabilities. One of the decisive factors is how functions and structures are addressed. This is necessary because function integration - among many others - affects material decisions and the manufacturing process chain. It is one of many reasons to rethink the product architecture and a way to support the design of resource-efficient products. Various strategies for function integration exist. However, there are currently no approaches in additive manufacturing that provide systematic support for early function integration.A systematic literature review identified 21 unique approaches. All approaches were categorized according to their abstraction level within a product architecture and their design type to be supported. They were then compared on the basis of their categorization, design objective and strategy for function integration to allow for a better understanding of when to use the approaches in research and practice. Key findings and considerations for adapting function integration approaches to early design stages are presented. In addition, several research gaps were identified.

Mechanistic kinetic modeling of the rhodium-catalyzed tandem hydroaminomethylation of 1-decene in a thermomorphic solvent system

For a more resource-efficient production of amines the homogeneously catalyzed tandem hydroaminomethylation reaction is of large relevance. The kinetics of the sulfoxantphos‑rhodium-catalyzed hydroaminomethylation of 1-decene were studied exploiting a thermomorphic solvent system. Focus was a mechanistic kinetic description of the enamine hydrogenation as the final step in the tandem reaction. Based on proposing a catalytic cycle and applying the Christiansen mathematics, a mechanistic rate model was derived and parameterized. The mechanistic model was able to describe the experimental observations in a broad range of operation conditions including pressure and temperature perturbations providing the basis for process design and optimization.

Promoting substitute aggregate system for the environmental-friendly geopolymer paver applications

Concerning the environmental imbalance caused by the over-exploitation of natural aggregates and the greenhouse emission of cementitious materials in the construction industry, in this paper, abundant laterite soil and natural coconut shells were used as partial substitutes for aggregate to make the cement-less geopolymer concrete a resource-efficient product. The effect of the alternative aggregate system in the geopolymer concrete was assessed in the aspects of strength and sustainability. The inclusion of laterite soil and coconut shell in the geopolymer resulted in 1.81 times improved toughness without significant change in the compressive strength. The use of laterite soil and coconut shell aggregates maintained the thermal stability up to 600 °C and reduces the consumption of 280 kg natural sand and 390 kg coarse aggregates while casting 1 m3 concrete, which supports to promote the alternative aggregate system for the efficient production of environmental-friendly geopolymer pavers.

Исследование свойств сплавов на основе кремниевой бронзы, напечатанных с применением технологии электронно-лучевого аддитивного производства

Introduction. Additive technologies make it possible to curb material expenses by reducing allowances for the final dimensional machining of workpieces. For such expensive materials as copper and copper alloys, this method is considerably attractive from a perspective of increasing resource efficiency in production. The operational properties of the C65500 alloy manufactured using additive technologies have not been fully studied and require additional research. The aim of the work is to study the structural and phase state, mechanical and operational properties of C65500 bronze specimens printed using electron beam additive manufacturing technology. In the work, specimens made of C65500 wire with different heat input values are studied, some of which were subjected to thermal treatment and mechanical processing, as well as specimens, manufactured using multi-wire technology. The work uses such research methods as the study of corrosion resistance of bronze specimens using a potentiostat, confocal laser scanning microscopy, friction tests and X-ray phase analysis. Results and discussion. Processing of specimens by plastic deformation (compression) and subsequent annealing leads to the most serious structural changes. Based on X-ray phase analysis, it is found that higher silicon content is observed in the case of the addition of silumins to bronze. The study of mechanical properties shows that the specimens, printed using multi-wire technology, have the highest strength properties. During tribological testing, fluctuations in the value of the friction coefficient are revealed, due to the scheme of the experiment and the combined adhesive-oxidative mechanism of specimens’ wear. The addition of 10 wt.% aluminum filament to bronze in the additive manufacturing process is an effective means for increasing the resistance of the material to electrochemical corrosion and increasing its wear resistance.

MEASURING RECYCLABILITY – A KEY FACTOR FOR RESOURCE EFFICIENY EVALUATION

The construction sector is one of the largest consumers of raw materials and energy, as well as a producer of CO2 in the European Union. To reduce environmental pollution and to preserve raw materials and energy, resource-efficient building elements must be designed. Even if laws demand resource-efficient product design in the building sector, there is no independent evaluation system for the resource efficiency of building elements (e.g., walls, roofs, floors). Such an evaluation should take the whole life cycle into account. The measurement of reusability and recyclability is therefore necessary. This article, therefore, describes the development of an evaluation system for reusability and recyclability to be included in resource efficiency assessment. Existing approaches and the special requirements of the building sector are considered. Finally, a practical example shows that the developed system is suitable for the assessment of reusability and recyclability. It can be used for the comparison of different construction methods or for the comparison of specific designs or products; thus, the evaluation system is helpful for architects as well as for product designers.

Feasibility study on multifrequency excitation of the melt pool during ultrasonic-assisted laser beam welding

The constantly increasing demands on components and their resource-efficient production require new strategies in modern process chains. The Collaborative Research Centre (CRC) 1153 “Tailored Forming” is working on the production of hybrid solid components made from joined semi-finished products with subsequent forming. Laser beam welding with ultrasonic assistance has proven to be advantageous in the production of semi-finished products due to the active influence on the microstructure as a result of the excitation. In this work, the feasibility of extending the monofrequency excitation of the melt pool used so far during welding to a multifrequency excitation is investigated. Results from simulations and experiments show that a multi-frequency excitation of the weld pool can be effectively realised. Furthermore, it is shown that a combination of previously separately used excitation methods (positioning of the melt pool in the vibration node and in the vibration antinode, respectively) with two different frequencies is successful and leads to a combination of effects as desired, what can be seen from micrographs.

Resource Efficient and Cleaner Production Assessment (RECP) in Pancoh Ecotourism Village, Regency of Sleman, Yogyakarta

This study aims to assess the Resource Efficiency and Cleaner Production (RECP) in tourism sector especially in Pancoh Ecotourism Village (PEV), Sleman. It assessed by using the RECP United Nations Industrial Development Organization (UNIDO) indicators for small and medium enterprise. It also used RECP assessment cycle method. The results show that there were two main activities that mostly use resources and energy in Pancoh Ecotourism Village (PEV), they are homestays and Pendopo. The use of energy in a homestay was bigger than in Pendopo. Also, inefficient use of energy and resources were found in homestays. The RECP recommendations for PEV were to use efficient stove, to use light-emitting diode (LED) lights and to attach magnets in the gas hose. If the PEV applied the recommendations, it has potential to reduce carbon by 22,535.68 CO2eq kg/year and it has potential to save IDR. 39,463,267/year. The indicators in RECP assessment for tourism village requires modifications since the pattern of resources and energy use in tourism villages is different from the small and medium enterprises that have implemented RECP method before

Elastic axial stiffness properties of lattice structures: Analytical approach and experimental validation for bcc and f2cc,z unit cells

Additive manufacturing (AM) is a key technology for the individualized and resource-efficient production of structural components. Recent developments in manufacturing technologies enable improved quality of additively manufactured components and therefore they become more and more important in lightweight constructions. An example is the substitution of solid material by porous lattice structures. Those embedded lattice structures lead to highly weight-efficient structures. Most recent investigations focus on numerical and experimental studies to describe the mechanical behavior of lattice structures. In this paper, a method to determine analytical expressions for the axial stiffness properties of lattice structures is presented. The displacement method and direct stiffness method are used to derive symbolic parameter-dependent formulas for the axial stiffnesses and effective Young’s moduli for f2cc,z, and bcc unit cells. Furthermore, an empirical approach based on Finite Element simulations is presented to describe the stiffness reduction for non-embedded or rather free lattice structures. The results are further validated by physical experiments. Stereolithography is used for specimen production. f2cc,z, and bcc lattice structures are embedded in thin-walled rectangular aluminum tubes and tested under compression load. Furthermore, lattices without a surrounding tube are tested. The analytical and empirical solutions are in good agreement with the experimental and numerical results.

Ultra-low Concentration of Cellulose Nanofibers (CNFs) for Enhanced Nucleation and Yield of ZnO Nanoparticles.

Cellulose nanofibers (CNFs) were used in aqueous synthesis protocols for zinc oxide (ZnO) to affect the formation of the ZnO particles. Different concentrations of CNFs were evaluated in two different synthesis protocols producing distinctly different ZnO morphologies (flowers and sea urchins) as either dominantly oxygen- or zinc-terminated particles. The CNF effects on the ZnO formation were investigated by implementing a heat-treatment method at 400 °C that fully removed the cellulose material without affecting the ZnO particles made in the presence of CNFs. The inorganic phase formations were monitored by extracting samples during the enforced precipitations to observe changes in the ZnO morphologies. A decrease in the size of the ZnO particles could be observed for all synthesis protocols, already occurring at small additions of CNFs. At as low as 0.1 g/L CNFs, the particle size decreased by 50% for the flower-shaped particles and 45% for the sea-urchin-shaped particles. The formation of smaller particles was accompanied by increased yield by 13 and 15% due to the CNFs’ ability to enhance the nucleation, resulting in greater mass of ZnO divided among a larger number of particles. The enhanced nucleation could also be verified as useful for preventing secondary morphologies from forming, which grew on the firstly precipitated particles. The suppression of secondary growths' was due to the more rapid inorganic phase formation during the early phases of the reactions and the faster consumption of dissolved salts, leaving smaller amounts of metal salts present at later stages of the reactions. The findings show that using cellulose to guide inorganic nanoparticle growth can be predicted as an emerging field in the preparation of functional inorganic micro/nanoparticles. The observations are highly relevant in any industrial setting for the large-scale and resource-efficient production of ZnO.

Digitalising food manufacturing

Digitalising food manufacturing

AMARETO – Saxon Alliance for MAterial‐ and Resource‐Efficient TechnOlogies

AMARETO – Saxon Alliance for MAterial‐ and Resource‐Efficient TechnOlogies