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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 June 2022) | Viewed by 42403

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Special Issue Editor

Prof. Dr. Marek Opielak

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Guest Editor

Faculty of Mechanical Engineering, Lublin University of Technology, 20-618 Lublin, Poland
Interests: biomaterials; plastics; performance; modeling; multilayer coatings; microstructure; sustainable development; energy and environmental efficiency; waste management/recycling

Special Issue Information

Dear Colleagues,

Along with the development of the global economy, factors related to environmental protection have become very important. New branches of science have been developed, including life cycle assessment (LCA). Life cycle estimation is a technique that studies environmental aspects and impacts over the entire life cycle of a product, the threat of which results from the selection of control factors for the management of production processes of their operation or intentional complex technical systems. At present, one should strive for intensive economic development based on bioeconomy principles. This approach requires the development of new material and product designs that, if properly prepared, will allow their reuse, repair, and recycling.

This Special Issue aims to collect research work presenting original research results, developed using innovative methods of integrated sustainability assessment, inspired by environmental assessment throughout the life cycle of machinery, equipment, and installations, using renewable energy sources.

We invite authors of full scientific articles, communications, and review articles to participate in this Special Issue. The most important research areas include:

Forecasting and modeling of energy and environmental efficiency of machines and material processing processes;
Eco-innovation systems for mechanical engineering of equipment machines, renewable energy installations, recycling, and material processing;
Assessment of the life cycle of machines and technical products;
Development of technical systems for the processing and production of materials;
Identification of waste and by-products in energy and environmental systems;
Clean energy systems;
Identification of indicators and process control methods for processing purposes.

Prof. Dr. Marek Opielak
Guest Editor

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

Life cycle estimation (LCA)
Circular economy
Sustainable development
Effectiveness of the production process
Energy and environmental efficiency
Waste management/recycling
Low carbon systems
Package materials
Processing and environmental processes

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Published Papers (12 papers)

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Research

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20 pages, 5151 KiB

Open AccessArticle

Synthesis of Micro- and Mesoporous Carbon Foams with Nanodispersed Metals for Adsorption and Catalysis Applications

by Roberto García, Elena Rodríguez, María A. Díez, Ana Arenillas, Sara F. Villanueva, Natalia Rey-Raap, Cristóbal Cuesta, María A. López-Antón and M. Rosa Martínez-Tarazona

Materials 2023, 16(4), 1336; https://doi.org/10.3390/ma16041336 - 4 Feb 2023

Cited by 3 | Viewed by 1962

Abstract

This work focuses on carbon foams, whose peculiarity is a predominant open macroporous cellular network that can be provided with tailored texture and morphology by the modification of the preparation process. The goal was to obtain macroporous carbonaceous structures capable of being activated by following a simple thermo-foaming procedure using a few reagents. With this purpose in mind, carbon foams with different textural properties were synthesized from sucrose using two foaming processes: at atmospheric pressure and in a pressurized reactor. Iron and silver nitrates added to sucrose gave rise, after carbonization, to materials with iron oxides and elemental silver particles nano-dispersed in the carbon matrix and promoted microporosity in both cases and mesoporosity in the case of iron nitrate. Iron nitrate also catalyzes the graphitization of the carbon material during carbonization. All these findings show the potential of sucrose thermo-foaming process as a viable and sustainable path to produce versatile carbon materials, capable of being used in various applications. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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17 pages, 26059 KiB

Open AccessArticle

Evaluating the Technology Readiness of a Ribbon-Blade Wind Turbine Using NASA’s TRL Method

by Robert Kasner and Patrycja Bałdowska-Witos

Materials 2021, 14(24), 7709; https://doi.org/10.3390/ma14247709 - 13 Dec 2021

Cited by 1 | Viewed by 2618

Abstract

The aim of this article was to complete a methodologically original study and evaluation of the technological readiness of an innovative ribbon-blade wind turbine in accordance with NASA’s TRL method. The structural form of the wind turbine unit analyzed herein, featuring a new ribbon turbine design, is distinguished by its safe durability. The circumferential speeds of the points on the turbine circumference were technologically verified positively and have a significant impact on the evaluation indicators of the conversion process, these being efficiency, unit energy consumption, and the quality of the power and energy of the wind power plant. The use of a new turbine design in the wind turbine analyzed herein, a working ribbon unit, resulted in a technological increase in efficiency from 13% to 32% and a reduction in unit internal energy consumption from 18% to 36% compared to the traditional wind turbine design. The TRL NASA-based evaluation herein, which consists of modern computer-aided engineering procedures (CAE standard) as well as IT instrumentation, and which includes nine degrees of technological readiness of an innovative ribbon windmill, falls in line with the standards for smart development based on knowledge and innovation (EU 2020 Strategy). Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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11 pages, 3696 KiB

Open AccessCommunication

Rochelle Salt-Based Ferroelectric and Piezoelectric Composite Produced with Simple Additive Manufacturing Techniques

by Etienne Lemaire, Damien Thuau, Jean-Baptiste De Vaulx, Nicolas Vaissiere and Atli Atilla

Materials 2021, 14(20), 6132; https://doi.org/10.3390/ma14206132 - 15 Oct 2021

Cited by 7 | Viewed by 3223

Abstract

More than one century ago, piezoelectricity and ferroelectricity were discovered using Rochelle salt crystals. Today, modern societies are invited to switch to a resilient and circular economic model. In this context, this work proposes a method to manufacture piezoelectric devices made from agro-resources such as tartaric acid and polylactide, thereby significantly reducing the energy budget without requiring any sophisticated equipment. These piezoelectric devices are manufactured by liquid-phase epitaxy-grown Rochelle salt (RS) crystals in a 3D-printed poly(Lactic acid) (PLA) matrix, which is an artificial squared mesh which mimics anatomy of natural wood. This composite material can easily be produced in any fablab with renewable materials and at low processing temperatures, which reduces the total energy consumed. Manufactured biodegradable samples are fully recyclable and have good piezoelectric properties without any poling step. The measured piezoelectric coefficients of manufactured samples are higher than many piezoelectric polymers such as PVDF-TrFE. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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33 pages, 6386 KiB

Open AccessArticle

Specification of Environmental Consequences of the Life Cycle of Selected Post-Production Waste of Wind Power Plants Blades

by Katarzyna Piotrowska and Izabela Piasecka

Materials 2021, 14(17), 4975; https://doi.org/10.3390/ma14174975 - 31 Aug 2021

Cited by 5 | Viewed by 2458

Abstract

Wind power plants during generation of electricity emit almost no detrimental substances into the milieu. Nonetheless, the procedure of extraction of raw materials, production of elements and post-use management carry many negative environmental consequences. Wind power plant blades are mainly made of polymer materials, which cause a number of problems during post-use management. Controlling the system and the environment means such a transformation of their inputs in time that will ensure the achievement of the goal of this system or the state of the environment. Transformations of control of system and environment inputs, for example, blades production, are describing various models which in the research methodology, like LCA (Life Cycle Assessment), LCM (Life Cycle Management), LCI (Life Cycle Inventory), etc. require meticulous grouping and weighing of life cycle variables of polymer materials. The research hypothesis was assuming, in this paper, that the individual post-production waste of wind power plant blades is characterized by a different potential impact on the environment. For this reason, the aim of this publication is to conduct an ecological and energy life cycle analysis, evaluation, steering towards minimization and development (positive progress) of selected polymer waste produced during the manufacture of wind power plant blades. The analyzes were based on the LCA method. The subject of the research was eight types of waste (fiberglass mat, roving fabric, resin discs, distribution hoses, spiral hoses with resin, vacuum bag film, infusion materials residues and surplus mater), which are most often produced during the production of blades. Eco-indicator 99 and CED (Cumulative Energy Demand) were used as the computation procedures. The influence of the analyzed objects on human health, ecosystem quality and resources was appraised. Amidst the considered wastes, the highest level of depreciating impact on the milieu was found in the life cycle of resin discs (made of epoxy resin). The application of recycling processes would decrease the depreciating environmental influence in the context of the total life cycle of all analyzed waste. Based on the outcome of the analyzes, recommendations were proposed for the environmentally friendly post-use management of wind power plant blades, that can be used to develop new blade manufacturing techniques that better fit in with sustainable development and the closed-cycle economy. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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22 pages, 3369 KiB

Open AccessArticle

Life Cycle Assessment of Two Alternative Plastics for Bottle Production

by Patrycja Bałdowska-Witos, Izabela Piasecka, Józef Flizikowski, Andrzej Tomporowski, Adam Idzikowski and Marcin Zawada

Materials 2021, 14(16), 4552; https://doi.org/10.3390/ma14164552 - 13 Aug 2021

Cited by 13 | Viewed by 5560

Abstract

The article characterizes selected issues related to the method of performing environmental impact analyses. Particular attention was paid to the need for identifying environmental effects associated with the process of shaping beverage bottles. This study concerns the analysis of selected stages of the machine’s life cycle environmental impact in the specific case of the blow molding machine used in the production of bottles. Life cycle assessment analysis was performed using the SimaPro 8.4.0 software (The Dutch Company Pre Consultants). The CML 2 and ReCiPe2016 methods were chosen to interpret the lists of chemical emissions. Impact categories specific to the CML 2 model are: abiotic depletion, acidification, eutrophication, global warming, ozone layer depletion, human toxicity, fresh water aquatic ecotoxicity, marine aquatic ecotoxicity, terrestrial ecotoxicity, and photochemical oxidation. Among all the considered impact categories, marine aquatic ecotoxicity was characterized by the highest level of potential harmful effects occurring during the bottle production process. A new aspect of the research is to provide updated and more detailed geographic data on Polish bottle production. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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23 pages, 6764 KiB

Open AccessArticle

Feasibility Study of Fluidic Sealing in Turbine Shroud

by Filip Wasilczuk, Pawel Flaszynski, Lukasz Pyclik and Krzysztof Marugi

Materials 2021, 14(13), 3477; https://doi.org/10.3390/ma14133477 - 22 Jun 2021

Cited by 5 | Viewed by 2088

Abstract

This paper analyses the methods for manufacturing turbine blades, focusing on the possibility of manufacturing slots in the region of the shroud. The reason for this analysis is the new flow control technique that can be used to limit the shroud leakage flow in a turbine—the air curtain. The air curtain uses a bypass slot to connect the upstream cavern of a shroud seal with the tip of a shroud fin. The bypass slot is an essential part of the solution, while at the same time introducing difficulties in the manufacturing process. Additionally, a parametric study on the bypass slot dimensions is performed using numerical simulations. The features of the numerical model and its validation against experimental data are presented. The parametric study includes the inlet and outlet dimensions, as well as the width of the slot. The most effective dimensions are shown, along with a possible explanation as to why they are the most effective. Interestingly, a slot that does not cover the whole span of the fin is more effective than a slot covering the whole span of the fin. This is caused by additional streamwise vortices that are created in the proximity of the bypass slot. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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15 pages, 6078 KiB

Open AccessArticle

Cutting Forces in Peripheral Up-Milling of Particleboard

by Bartosz Pałubicki

Materials 2021, 14(9), 2208; https://doi.org/10.3390/ma14092208 - 25 Apr 2021

Cited by 6 | Viewed by 2387

Abstract

An analysis of forces acting in the peripheral up-milling of particleboard is presented. First, a novel method of high-frequency piezoelectric force signal treatment is proposed and used to separate the original force signal from the vibrations of the previous cutting iteration. This allows for the analysis of single chip cutting force courses during industrial CNC (Computer Numerical Control) milling. The acting forces are compared with the theoretical, instantaneous, uncut chip thickness. The results show that, for a range of 40–60 m/s, the higher the cutting speed used, the higher the resultant and principal cutting forces. The method of cutting thrust force used was similar to that observed in solid wood milling, i.e., first using a pushing action, followed by a pulling action. The obtained average specific principal cutting forces for particleboard peripheral up-milling are equal to 32.0 N/mm² for slow and 37.6 N/mm² for fast milling. The specific cutting thrust force decreases with the increase in instantaneous uncut chip thickness. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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27 pages, 5948 KiB

Open AccessArticle

Theoretical Studies of the Interaction between Screw Surface and Material in the Mixer

by Andrzej Marczuk, Vasily Sysuev, Alexey Aleshkin, Petr Savinykh, Nikolay Turubanov and Andrzej Tomporowski

Materials 2021, 14(4), 962; https://doi.org/10.3390/ma14040962 - 18 Feb 2021

Cited by 7 | Viewed by 2753

Abstract

Mixing is one of the most commonly used processes in food, animal feed, chemical, cosmetic, etc., industries. It is supposed to provide high-quality homogenous, nutritious mixtures. To provide appropriate mixing of materials while maintaining the process high efficiency and low energy consumption it is crucial to explore and describe the material flow caused by the movement of mixing elements and the contact between particles. The process of mixing is also affected by structural features of the machine components and the mixing chamber, speed of mixing, and properties of the mixed materials, such as the size of particles, moisture, friction coefficients. Thus, modeling of the phenomena that accompany the process of mixing using the above-listed parameters is indispensable for appropriate implementation of the process. The paper provides theoretical power calculations that take into account the material speed change, the impact of the material friction coefficient on the screw steel surface and the impact of the friction coefficient on the material, taking into account the loading height of the mixing chamber and the chamber loading value. Dependencies between the mixer power and the product degree of fineness, rotational speed of screw friction coefficients, the number of windings per length unit, and width of the screw tape have been presented on the basis of a developed model. It has been found that power increases along with an increase in the value of these parameters. Verification of the theoretical model indicated consistence of the predicted power demand with the power demand determined in tests performed on a real object for values of the assumed, effective loading, which was 65–75%. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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10 pages, 1240 KiB

Open AccessArticle

Feed Force and Sawdust Geometry in Particleboard Sawing

by Bartosz Pałubicki, Luďka Hlásková, Stephan Frömel-Frybort and Tomasz Rogoziński

Materials 2021, 14(4), 945; https://doi.org/10.3390/ma14040945 - 17 Feb 2021

Cited by 12 | Viewed by 2751

Abstract

The measurement of cutting forces permits building of physic-mechanical cutting models for a better understanding of the phenomena observed during cutting. It also permits the design and optimization of processes, machines, tools, and wood preparation. Optimization of cutting conditions of wood-based materials can decrease the cutting forces, which directly relates to the energy consumption and surface quality. The sawdust analysis may serve for analysis of cutting kinematics and occupational health risk. The aim of the study was to estimate the correlation between the feed rate and both feed force and sawdust particle size produced during particleboard circular sawing. A saw machine type K700 was used in experiments. There were three feed rates of 12, 18, and 24 m/min executed by a horizontal pneumatic actuator fixed to the sliding side table of the saw machine. Based on the results of the experiments, a positive correlation was observed between the feed rate in a circular sawing process and feed forces and an unexpected particle size distribution depending on the feed rate. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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21 pages, 2286 KiB

Open AccessEditor’s ChoiceArticle

Manufacturing and Recycling Impact on Environmental Life Cycle Assessment of Innovative Wind Power Plant Part 1/2

by Krzysztof Doerffer, Patrycja Bałdowska-Witos, Michał Pysz, Piotr Doerffer and Andrzej Tomporowski

Materials 2021, 14(1), 220; https://doi.org/10.3390/ma14010220 - 5 Jan 2021

Cited by 10 | Viewed by 3860

Abstract

Wind power plants are considered as an ecologically-clean source of energy. However, manufacturing processes cannot be treated that way. Manufacturing processes consume huge amounts of electrical and thermal energy and significant amount of materials, e.g., steel, polymers, oils, and lubricants. All of the above could be potentially harmful for environment. There are not many works and publications regarding life-cycle analysis of wind power plants. This study’s objective is to use LCA (Life Cycle Assessment) to the manufacturing and utilization of a specific drag force-driven wind turbine. The discussed innovative wind turbine is of the type that assures safety for prosumer application. Drag force-driven turbines become more heavy than other types of lift driven turbines, but at the same time, their characteristic provides opportunity to use easily recyclable materials instead of materials like plastics or composites. The wider look through LCA tools, may change the perspective of view at that type of wind turbines. Analyzed turbine has capacity of 15 kW and is located in Poland. LCA was carried out using Eco-indicator 99 method in eleven impact categories. Among all of the turbine components, the highest negative impact was noted in the case of the tower. The wind turbine under consideration is characterized by high recycling potential. According to the presented research, recycling provides around 30% reduction of the environmental impact. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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23 pages, 4789 KiB

Open AccessArticle

Manufacturing and Recycling Impact on Environmental Life Cycle Assessment of Innovative Wind Power Plant Part 2/2

by Patrycja Bałdowska-Witos, Krzysztof Doerffer, Michał Pysz, Piotr Doerffer, Andrzej Tomporowski and Marek Opielak

Materials 2021, 14(1), 204; https://doi.org/10.3390/ma14010204 - 4 Jan 2021

Cited by 2 | Viewed by 3255

Abstract

The process of conversion of wind kinetic energy into electricity in innovative wind power plant emits practically no harmful substances into the environment. However, the production stage of its components requires a lot of energy and materials. The biggest problem during production planning process of an innovative wind power plant is selection of materials and technologies and, consequently, the waste generated at this stage. Therefore, the aim of this publication was to conduct an environmental analysis of the life cycle of elements of a wind turbine by means of life cycle assessment (LCA) method. The object of the research was a wind power plant divided into five sets of components (tower, turbine structure, rotors, generators, and instrumentation), made mainly of steel and small amounts of polymer materials. Eco-indicator 99 was used as an analytical procedure. The impact of the subjects of analysis on human health, ecosystem quality and resources was assessed. Among the analyzed components, the highest level of negative impact on the environment was characterized by the life cycle of the wind turbine tower. The application of recycling processes is reducing the negative impact on the environment in the perspective of the entire life cycle of all studied elements of the wind power plant construction. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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Review

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28 pages, 2640 KiB

Open AccessReview

Recent Attempts in the Design of Efficient PVC Plasticizers with Reduced Migration

by Joanna Czogała, Ewa Pankalla and Roman Turczyn

Materials 2021, 14(4), 844; https://doi.org/10.3390/ma14040844 - 10 Feb 2021

Cited by 77 | Viewed by 7939

Abstract

This paper reviews the current trends in replacing commonly used plasticizers in poly(vinyl chloride), PVC, formulations by new compounds with reduced migration, leading to the enhancement in mechanical properties and better plasticizing efficiency. Novel plasticizers have been divided into three groups depending on the replacement strategy, i.e., total replacement, partial replacement, and internal plasticizers. Chemical and physical properties of PVC formulations containing a wide range of plasticizers have been compared, allowing observance of the improvements in polymer performance in comparison to PVC plasticized with conventionally applied bis(2-ethylhexyl) phthalate, di-n-octyl phthalate, bis(2-ethylhexyl) terephthalate and di-n-octyl terephthalate. Among a variety of newly developed plasticizers, we have indicated those presenting excellent migration resistance and advantageous mechanical properties, as well as those derived from natural sources. A separate chapter has been dedicated to the description of a synergistic effect of a mixture of two plasticizers, primary and secondary, that benefits in migration suppression when secondary plasticizer is added to PVC blend. Full article

(This article belongs to the Special Issue Recent Developments in Pro-ecological Materials and Processes)

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