REMADE Institute: Advancing the Nation in Sustainable Manufacturing

Advancing the Nation in Sustainable Manufacturing

Impact Report 2018

About the

The Sustainable Manufacturing Innovation Alliance was selected by the U.S. Department of Energy to lead its new Reducing Embodied-Energy And Decreasing Emissions (REMADE) Institute. This national coalition of leading universities and companies is forging new clean energy initiatives deemed critical in keeping U.S. manufacturing competitive. The mission of the REMADE Institute is to enable the early stage applied research and development of key indus- trial platform technologies that could dramatically reduce the embodied energy and carbon emissions associated with industrial-scale materials production and processing. By focusing our efforts on addressing knowledge gaps that will eliminate and/or mitigate the technical and economic barriers that prevent greater material recycling, recovery, remanufacturing and reuse, the REMADE Institute seeks to motivate the subsequent industry investments required to advance technology development that will support the U.S. manufacturing eco-system.

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A Message from the Chief Executive Officer

Looking back over the past year, I am proud of the remarkable progress made since the launch of the Reducing Embodied Energy and Decreasing Emissions (REMADE) Insti- tute in May 2017. REMADE is the 14th Institute in the Manufacturing USA network, and is focused on technologies essential to reuse, recycle, and remanufacture materials such as metals, fibers, polymers and electronic waste. During its first year, REMADE established independent operations in Rochester, New York and was pleased to add new headquarters staff with years of accomplishments in business, research, and government. We also engaged a national member network of industrial, academic, and national lab partners. Driven by industry input, a technology roadmap was created, project calls held, and the first projects selected for award. As the Institute transitions from startup to full operation, the effort is focused on developing transformational technologies to significantly reduce energy consumption in U.S. manufacturing, while increasing material recycling, recovery, remanufacturing and reuse. Workforce development is also a priority, ensuring the U.S. workforce is prepared to deploy and manufacture REMADE-relevant technologies. We have a golden opportunity like never before in the history of industry, we have funding, a huge national plan for what to do and significant partnerships. Now it is up to all of us to execute this plan. Execution is everything. Thanks to the support of our consortium partners, and financial funding from the U.S. Department of Energy, REMADE is well positioned to deliver transformational technologies that advance the nation in sustainable manufacturing.

Nabil Nasr Chief Executive Officer REMADE Institute

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On January 4, 2017, the U.S. Department of Energy announced the launch of the Reduced Embodied-energy and Decreasing Emissions (REMADE) Institute headquartered in Rochester, New York and led by the Sustainable Manufacturing Innovation Alliance. REMADE is the Department of Energy’s fifth manufacturing institute within the multi-agency Manufacturing USA network. REMADE is focused on driving down the cost of technologies essential to reuse, recycle and remanufacture materials such as metals, fibers, polymers and electronic waste. This is expected to save the U.S. manufacturing base billions in energy costs and will strengthen the nation’s economic competitiveness through cutting-edge innovation. REMADE is pursuing this mission by: Enabling early stage applied research and development of key industrial platform technologies that could dramatically reduce the embodied energy and carbon emissions associated with industrial-scale materials production and processing. Eliminate and/or mitigate technical and economic barriers that prevent greater material recycling, recovery, remanufacturing, and reuse. Accelerating Innovation for the Circular Economy

Basic Research

Research to Address Knowledge Gaps and Prove Feasibility

Technology Development and Demonstration

Deployment

Facilitated by DOE Funding Facilitated by Industry Funding

Performance Goals

Cross Industry Reuse

Cost Parity

30%

25%

20%

30%

Reduction of primary feedstock consumption and increase secondary feedstock by 30%.

Reduction of energy demand for secondary feedstock processing by 30%.

Improvements in embodied energy efficiency.

10x reduction in primary material feedstock and 20% reduction in associated GHG.

Enable cross- industry reuse of recycled feedstock.

Achieve cost parity for secondary materials.

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Technical Focus Areas and Research Activities

Polymers

E-Waste

Metals

Fibers

To achieve its mission and overcome these challenges, the REMADE Institute has organized its activities around five nodes and material classes of metals, polymers, e-waste, and fibers. Four nodes align to the material life cycle stages: Design for Re-X , Manufacturing Materials Optimization , Remanufacturing & End-of-life Reuse , and Recycling & Recovery ; the fifth node, Systems Analysis & Integration , addresses systems-level issues that are broader in scope than any one particular node and have the potential to impact all the nodes. Each node will pursue research activities focused on overcoming challenges in the following areas:

Systems Analysis and Integration Data collection, standardization, metrics, and tools for understanding material flow.

Manufacturing Materials Optimization Technologies to reduce in-process losses, reuse scrap materials, and utilize secondary feedstock in manufacturing.

Recycling & Recovery Rapid gathering, identification, sorting, separation, containment removal,

reprocessing, and disposal.

Remanufacturing & EOL Reuse Efficient and cost effective technologies for cleaning component restoration, condition

Design for Re-X Design tools to improve material utilization and reuse at End-of-Life (EOL).

assessment, and reverse logistics.

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Membership Update REMADE is driving collaboration among its diverse membership including the automotive, apparel, and consumer goods industries. From small businesses and large corporations to a strong network of universities and national labs, REMADE members are discovering better ways to recycle and recover valuable materials, develop new processes for remanufacturing and end-of-life reuse, and infuse sustainability into product design.

73 MEMBERS AND GROWING

33 INDUSTRY MEMBERSREPRESENTING MORE THAN 640,000 EMPLOYEES

25 ACADEMIC MEMBERS

11 TRADE ASSOCIATIONS & AFFILIATES

55% OF INDUSTRY MEMBERS ARE SMALL TO MEDIUM SIZED ENTITIES

4 NATIONAL LABS

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REMADE Member Organizations

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Institute Highlights

 Department of Energy announced REMADE Institute in January and released funding in May  REMADE Headquarters established in Rochester, New York, and leadership team in place  Remadeinstitute.org, social media accounts, and marketing collaterals created  Membership agreement approved and 1 st member welcomed in October  Governance structure staffed with member representatives  Workforce development plan developed and member committee engaged

2017

 Technology Roadmap workshop held in Rochester, New York  Methodology and templates for issuing project calls established  Three foundational projects selected for award

 The Technology Roadmap was published to membership after extensive preparation including member surveys, in-person workshops, external review panels, Department of Energy input, and Technical Leadership Committee research  Project Call 1.0 was announced in January  Interviews were conducted to identify member research needs and priorities for incorporation into the technology roadmap update  REMADE relevant occupations, skills, and competencies were identified to support education and training development  17 public-private partnership projects totaling $10M were selected for award from the first project call  A calculator tool was provided to members with guidance on how to calculate material efficiency and embodied energy benefits for proposals and projects  Project Call 2.0 was announced at the Fall 2018 Member meeting

2018

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Foundational Projects The REMADE Institute was pleased to announce three foundational projects focused on the recycling and recovery of paper, fibers, and e-waste. These three projects marked the institute’s first official step toward achieving its objective of improving sustainable manufacturing in the U.S.

Platform Technology for Selective Recovery of Polymers and Residual Metals from Complex Polymeric Content Waste Streams, including e-Waste – Argonne National Laboratory This project will evaluate, validate, and confirm the effectiveness of a platform for selective materials separation technology that enables recovery of ABS, PS, ABS/PC alloy and PC from e-waste and other complex polymeric content waste streams. Benefits include increasing secondary materials, primarily polymers, by as much as 3.5 million ton/yr (> 100% increase vs. baseline), recovering more than 350 trillion Btu of embodied energy, and reducing GHG emissions by 17.4 MMTCO2e.

Assessment of the Impact of Single Stream Recycling on Paper Contamination in Recovery Facilities and Paper Mills – University of Miami This project will evaluate the impact of single stream recycling (SSR) on paper contamination in recovery operations and explore emerging recovery processes for minimizing fiber contamination. The benefits include reducing costs by $10M, reducing energy by 100tBtu/yr, and reducing CO2 emissions by 450 MMTCO2e for every 1M metric tons of material recovered.

Rapid Sorting of Scrap Metals with Solid State Device – University of Utah This project focuses on improving the separation of non-ferrous scrap metals from other non-ferrous metals using electrodynamic sorting (EDX) at high throughput and with greater purity and yield. The results will enable energy reduction of 300 trillion BTU/yr (TBtu/yr) and reduce GHG emissions by the equivalent of 15 million tons of CO2 per year.

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First Project Call: Project Summaries After receiving more than 106 letters of intent for proposals after Project Call 1.0, the REMADE Institute announced 17 public-private partnership projects with a total value of $10M (cost-share contribution and $4M in federal funding). Together, these projects represent partnerships from 30 organizations across industry, academia, national labs, and trade associations.

Remanufacturing & End-of-Life Reuse

Design for Re-X

Development of an Industrially Relevant RE-SOLAR Design Framework – University of Pittsburgh , University of California-Irvine , National Renewable Energy Laboratory , First Solar . SNAPSHOT: Solar modules are creating a major surge in e-waste because inadequate attention is focused on designing for recycling or reuse. This project provides a design framework of high-efficiency modules that can be economically recycled, recovered, remanufactured, and/or reused. Increasing Melt Efficiency and Secondary Alloy Usage in Aluminum Die Casting – Ohio State University , Alcoa USA Corp. , North American Die Casting Association . SNAPSHOT: The aluminum casting industry uses limited quantities of secondary alloys because of their poor quality (i.e. high concentrations of residual contaminants such as iron). In this project thermodynamic and kinetic models coupled with experimental validation and testing will be used to develop holistic contaminant control techniques including alloy, flux and refractory chemistries to increase melt efficiencies with higher levels of secondary materials use. Manufacturing Material Optimization

In-situ Nondestructive Evaluation of In-flight Particle Dynamics and Intrinsic Properties for Thermal Spray Repairs – Iowa State University , John Deere . SNAPSHOT: The quality of coated surfaces from thermal spray repairs is determined by the particles impacting the surface. A better understanding of in-flight particle dynamics will enable improved success rates for repairs in the remanufacturing industry. Remaining Life Determination – Rochester Institute of Technology , University of Illinois at Urban-Champaign , Caterpillar . SNAPSHOT: Non-destructive methods to measure accumulated mechanical damage (i.e., fatigue) prior to failure do not exist. Research will focus on methods to reliably detect features associated with early stage fatigue damage to predict the remaining useful life of the part. Non-Destructive In-process Assessment of Thermal Spray Repairs – Rochester Institute of Technology , University of Pittsburgh , ITAMCO , Caterpillar . SNAPSHOT: Thermal spray process inspection is currently lot-based which can result in the rejection of entire lots of parts due to process variation. This project will focus on development of non-destructive in-process evaluation of thermal spray to minimize reject rates of good parts.

NOTE: projects are selected for award pending final negotiation and DOE approval.

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Recycling & Recovery

Quantitative Non-Destructive Evaluation of Fatigue Damage Based on Multi-Sensor Fusion – University of Illinois at Urbana-Champaign , Penn State University . SNAPSHOT: Current single-sensor non-destructive fatigue damage evaluation techniques have limited accuracy in predicting actual fatigue damage and the remining useful life of a recovered part. The integration of multiple sensors which respond differently to fatigue damage has the potential of increasing the predictive accuracy of remaining useful life of materials to enable higher remanufacturing rates of parts. Epoxy/Silicon Potting Material Removal for Greater Recovery of Circuit Boards – Rochester Institute of Technology , Caterpillar , CoreCentric Solutions . SNAPSHOT: More cost-effective technologies are needed to remove coating or potting materials from circuit boards to enable repair and reuse. Two alternative technologies, laser ablation and micro-media blasting, will be tested and evaluated to quantify cost-effectiveness relative to industry specified cost targets. Condition Assessment of Used Electronics – Rochester Institute of Technology , Caterpillar , CoreCentric Solutions . SNAPSHOT: Detecting solder joint and interconnection failures on used electronics presents a serious cost chal- lenge for remanufacturers because detection is currently completed manually. Several automated methods for detection of these failures will be examined to determine their feasibility for use in the remanufacturing industry.

Development of New Cost-Effective Methods for Removing Trace Contaminants in Recycled Metals – Ohio State University , Alcoa , Computherm SNAPSHOT: Cost-effective technologies for the in-melt removal and/or neutralization of trace contaminants in metals is critical for secondary feedstocks to achieve cost parity with primary feedstocks. This exploratory project will experimentally evaluate the addition of “scoping” elements in molten aluminum to neutralize trace contaminants that would otherwise constrain the recycling of aluminum. Pushing the State of the Art in Steel Recycling through Innovation in Scrap Sorting and Impurity Removal – Colorado School of Mines SNAPSHOT: Increasing the utility of steel scrap through innovation in sorting and impurity removal will increase the use of secondary feedstock and achieve cost parity for secondary materials for steel products. This study will investigate: 1) physical methods such as optical sorting to upgrade scrap steel and 2) chemical or met- allurgical treatment methods to remove or neutralize the effect of impurities in molten steel. Determining Material, Environmental and Economic Efficiency of Sorting and Recycling Mixed Flexible Packaging and Plastic Wrap – American Chemistry Council , Resource Recycling Systems , Idaho National Laboratory SNAPSHOT: This project will further develop technology to recover flexible plastic film from a

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material recovery facility (MRF). Market opportunities for the recovered film will be examined and the resulting economic and environmental impacts will be evaluated. The technology to be developed in the project, if implemented broadly, has the potential of capturing almost 11 billion pounds of flexible plastic packaging and plastic wrap that is currently landfilled each year. Evaluation of Logistics Systems for the Collection, Preprocessing and Production of Secondary Feedstocks from E-waste – Idaho National Laboratory , Sunnking SNAPSHOT: The objective of this project is to develop an e-waste logistics model that integrates transportation, manufacturing processes, and markets to enable opti- mal recovery and recycling of e-waste. The model will enable identification of least cost options for increasing e-waste collection and recycling. Demineralization of Carbon Black Derived from End-of-Life Tires – University of Utah , OTR Wheel Engineering/Green Carbon Inc. , and Idaho National Laboratory SNAPSHOT: Alternative process technologies will be experimentally evaluated to upgrade carbon black recovered from end-of-life tires to meet carbon black market quality specifications. Approximately 3.87 Mt of waste tires accrue every year in the United States. If all these tires were processed to recover the carbon black, about 1.1 Mt of carbon black could be recovered to use as a secondary feedstock. Scalable High Shear Catalyzed Depolymerization of Multilayer Plastic Packaging – University of Massachusetts-Lowell , Michigan State , Unilever , ACC , National Renewable Energy Laboratory SNAPSHOT: Industry is increasingly combining layers of different polymer materials to construct highly functional, lightweight packaging (e.g. to extend food life). These multilayer films are unfortunately less recyclable than single layer films. This project will investigate catalytic depolymerization as a cost-effec- tive approach to process these films into higher value products suitable for use in a variety of applications.

Systems Analysis & Integration

Systems Analysis for PET and Olefin Polymers in a Global Circular Economy – Michigan Technological University , American Chemistry Council , Idaho National Laboratory SNAPSHOT: This exploratory project will develop a framework for systems analysis of PET and polyolefins in the context of a circular economy. These polymeric materials are currently recycled at low rates in the U.S., but are among the largest volumes of polymeric materials that are recyclable. The objective of this project is to develop a framework that will enable analyses of factors such as new recovery technologies that might enhance the recovery and recycle of polymers including polyolefins and PET. Mapping the Material Base for REMADE – Yale University , Unilever , International Zinc Association , Massachusetts Institute of Technology SNAPSHOT: This project will develop a materials flow baseline for REMADE materials (metals, fibers, polymers, and e-waste) to support measurement of the impact of future technology improvements through REMADE projects. A harmonized and validated set of data for metals, fibers, polymers and e-waste will be developed within a consistent framework that allows comparisons of material efficiencies across REMADE materials at all life-cycle stages. Assessment of Opportunities and Technologies for Reducing Energy Consumption through SNAPSHOT: The goal of this project is to develop an operational tool for the quantification of energy savings and emission reductions resulting from technology development carried out within REMADE. The tool will be based on the National Renewable Energy Laboratory’s MFI tool (Materi- als Flow though Industry) which will be enhanced to include flows and process technologies relevant to materials recov- ery and recycling. Illustrative case studies based on metal and e-waste will conducted. Resource Recovery – Yale University , Massachusetts Institute of Technology , National Renewable Energy Laboratory

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Providing education and training in sustainable manufacturing is critical for the U.S. to achieve a true shift to a circular economy. In 2018, REMADE conducted a labor analysis to identify the relevant occupations and competencies required of the current workforce to achieve the institute’s objectives. Education and Workforce Development

REMADE’s education and workforce plan outlines the strategies to meet the following objectives:  Identify and map the necessary skills for REMADE technologies.  Baseline existing relevant content and partnerships supportive of REMADE.  Respond with curricula and training options that support current and future-state workforce needs. – Identify appropriate stackable certificate and degree programs.

– Identify opportunities for continuing professional development for existing workforce. – Leverage existing networks and national partners for dissemination and delivery.

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Clean Energy, Innovation & Sustainability.

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MANUFACTURING FOR A SUSTAINABLE FUTURE.

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Acknowledgment: “This material is based upon work supported by the U.S. Department of Energy’s Office of Energy Efficiency and Renewable Energy (EERE) under the Advanced Manufacturing Office Award Number DE-EE0007897.” Disclaimer: “This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof.”