Sustainability analysis for new technologies of biofuels and Additive Manufacturing

138 Pages·2017·2.21 MB·English

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Doctoral Dissertations Graduate School
8-2017
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Nelson A. Granda Marulanda
University of Tennessee, Knoxville, [email protected]
Follow this and additional works at: https://trace.tennessee.edu/utk_graddiss
Part of the Industrial Technology Commons, and the Systems Engineering Commons
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Granda Marulanda, Nelson A., "Sustainability analysis for new technologies of biofuels and Additive
Manufacturing. " PhD diss., University of Tennessee, 2017.
https://trace.tennessee.edu/utk_graddiss/4622
This Dissertation is brought to you for free and open access by the Graduate School at TRACE: Tennessee
Research and Creative Exchange. It has been accepted for inclusion in Doctoral Dissertations by an authorized
administrator of TRACE: Tennessee Research and Creative Exchange. For more information, please contact
[email protected].
To the Graduate Council:
I am submitting herewith a dissertation written by Nelson A. Granda Marulanda entitled
"Sustainability analysis for new technologies of biofuels and Additive Manufacturing." I have
examined the final electronic copy of this dissertation for form and content and recommend
that it be accepted in partial fulfillment of the requirements for the degree of Doctor of
Philosophy, with a major in Industrial Engineering.
Mingzhou Jin, Major Professor
We have read this dissertation and recommend its acceptance:
Sachin U. Nimbalkar, Oleg Shylo, Robert M. Counce
Accepted for the Council:
Dixie L. Thompson
Vice Provost and Dean of the Graduate School
(Original signatures are on file with official student records.)
Sustainability analysis for new technologies of biofuels and
Additive Manufacturing

A Dissertation Presented for the
Doctor of Philosophy
Degree
The University of Tennessee, Knoxville

Nelson A. Granda Marulanda
August 2017
DEDICATION

Dedico mi trabajo y esfuerzo en honor mi toda familia Granda Marulanda y
Pacheco Del Río. En especial a mi esposa Zuania, mis padres Ana y Nelson, y a
mis hermanos Laura y Sebastián. También a mi familia extendida Gaby, Vane, y
Bárb. A todos los que de alguna manera u otra me han apoyado durante todas
las etapas de mi vida.

¡Muchas Gracias!
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ACKNOWLEDGEMENTS
I want to extend a grateful thanks to:
My advisors, Dr. Mingzhou Jin and Dr. Sachin Nimbalkar. ORNL MDF staff
specially Daryl Cox, and Derek Siddle. To the members of my committee, Dr.
Oleg Shylo and Dr. Robert Counce.
To the University of Tennessee Industrial and Systems Engineering department,
especially Yvette for all the support. To EPRI and AmericaMakes for supporting
my work.
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ABSTRACT
This work is a compendium of different sustainability analysis on new
technologies. The first chapter performed a Life Cycle Analysis of a biofuel
process where pine woodchips are used to create SynGas. The study was done
using a 10 tons gasifier, the mass balance of the reaction and an input/output
analysis. All the data obtained was input into a freeware LCA software and the
results were compared to the use of regular produced natural gas. The second
chapter creates a benchmark of energy intensity and presents a case using
binder jetting technology. Different Additive Manufacturing technologies energy
intensity was reported, when possible a NIST artifact created to standardize
measurements for AM was used. The third Chapter used three aerospace parts
to compare new designs for Additive Manufacturing and their energy impact to
conventional manufacturing processes. For this analysis the ORNL energy
impact assessment tool was used.

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TABLE OF CONTENTS

INTRODUCTION .................................................................................................. 1
References ........................................................................................................ 3
CHAPTER I Life-cycle Assessment of Bio-fuel Production using Syngas from
Biomass ................................................................................................................ 4
Abstract ............................................................................................................. 5
Introduction ....................................................................................................... 6
LCA Background and Methodology ............................................................. 10
Goal and Scope Definition ........................................................................... 11
Life-Cycle Inventory (LCI) Analysis .............................................................. 17
Life Cycle Inventory Impact assessment ..................................................... 18
Interpretation of LCA .................................................................................... 20
LCA Study on the Production of Biofuel from Wood Biomass through Synthetic
Natural Gas ..................................................................................................... 21
Case Introduction ......................................................................................... 21
Software Used in the Study ......................................................................... 28
Case Goal and Scope .................................................................................. 28
Inventory Assessment for the Case ............................................................. 32
Impact Assessment ..................................................................................... 39
Recommendations and Discussion .............................................................. 43
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References ...................................................................................................... 45
CHAPTER II Energy Efficiency Benchmarking on Additive Manufacturing
processes ........................................................................................................... 49
Abstract ........................................................................................................... 50
Introduction ..................................................................................................... 50
Literature Review ............................................................................................ 56
Energy Consumption Analysis Framework for Additive Manufacturing ........... 65
Power monitoring setup ............................................................................... 65
NIST Standard Artifact ................................................................................. 68
Energy Intensity previous work in Additive Manufacturing ........................... 70
Case with Binder Jet .................................................................................... 77
Discussion ....................................................................................................... 85
References ...................................................................................................... 91
CHAPTER III Life-Cycle Energy Assessment of aerospace 3d printed parts ..... 94
Abstract ........................................................................................................... 95
Introduction ..................................................................................................... 95
Sustainability and Life Cycle Assessment ................................................... 95
AM Energy Impact Assessment Tool ........................................................... 99
Literature Review .......................................................................................... 102
Methods ........................................................................................................ 106
Results .......................................................................................................... 109
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References .................................................................................................... 122
CONCLUSION .................................................................................................. 124
VITA .................................................................................................................. 125

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LIST OF TABLES

Table 1.1 Data from experimental results obtained from the pilot gasifier .......... 33
Table 1.2 Processes used in the model .............................................................. 34
Table 1.3 Inventory input results for the use stage of the LCA ........................... 35
Table 1.4 Inventory output results for use stage of the LCA ............................... 37
Table 1.5 Impact assessment results for all stages of the system ...................... 40
Table 1.6 Carbon Dioxide Emissions Coefficients by Fuel type .......................... 42
Table 2.1 ASTM categorization of Additive manufacturing ................................. 54
Table 2.2 ECR by process .................................................................................. 58
Table 2.3 ECR by process and material thick layer ............................................ 60
Table 2.4 Specific Energy Consumption by technology ...................................... 62
Table 2.5 Energy intensity data of various Additive Manufacturing systems ....... 72
Table 2.6 Energy Intensity Data Binder-Jetting ................................................... 84
Table 3.1 Companies data survey compilation ................................................. 110
Table 3.2 Company one numeric results .......................................................... 115
Table 3.3 Company two numeric results ........................................................... 116
Table 3.4 Company three numeric results ........................................................ 117
Table 3.5 Summary of Total energy used per part ............................................ 120

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