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Industrial networks consist of multiple industrial nodes interacting with each other through material exchanges that support the overall production goal of the network.

 

Mapping material flows in an economy is crucial to identifying strategies for resource management toward lowering the waste and environmental impacts of society, a key objective of research in industrial ecology. However, constructing models for mapping material flows at a sectoral level, such as in physical input–output tables (PIOTs) at highly disaggregated levels, is tedious and relies on a large amount of empirical data. To overcome this challenge, a novel collaborative cloud platform PIOT-Hub is developed in this work. This platform utilizes a Python-based simulation system for extracting material flow data from mechanistic models, thus semi-automating the generation of PIOTs. The simulation system implements a bottom-up approach of utilizing scaled engineering models to generate physical supply tables (PSTs) and physical use tables (PUTs) which are converted to PIOTs (described in (Vunnava & Singh, 2021)). Mechanistic models can be uploaded by users for sectors on PIOT-Hub to develop PIOTs for any region. Both models and resulting PST/PUT/PIOTs can be shared with other users utilizing the collaborative platform. The automation and sharing features provided by PIOT-Hub will help to significantly reduce the time required to develop PIOT and improve the reproducibility/continuity of PIOT generation, thus allowing the study of the changing nature of material flows in regional economy. In this paper, we describe the simulation system MFDES and PIOT-Hub architecture/functionality through a demo example for creating PIOT in agro-based sectors for Illinois. Future work includes scaling up the cloud infrastructure for large scale PIOT generation and enhancing the tool compatibility for different sectors in economy. 

Dynamical equations form the basis of design for manufacturing processes and control systems; however, identifying governing equations using a mechanistic approach is tedious. Recently, Machine learning (ML) has shown promise to identify the governing dynamical equations for physical systems faster. This possibility of rapid identification of governing equations provides an exciting opportunity for advancing dynamical systems modeling. However, applicability of the ML approach in identifying governing mechanisms for the dynamics of complex systems relevant to manufacturing has not been tested. We test and compare the efficacy of two white-box ML approaches (SINDy and SymReg) for predicting dynamics and structure of dynamical equations for overall dynamics in a distillation column. Results demonstrate that a combination of ML approaches should be used to identify a full range of equations. In terms of physical law, few terms were interpretable as related to Fick’s law of diffusion and Henry’s law in SINDy, whereas SymReg identified energy balance as driving dynamics. 

Sustainable transition to low carbon and zero waste economy requires a macroscopic evaluation of opportunities and impact of adopting emerging technologies in a region. However, a full assessment of current physical flows and wastes is a tedious task, thus leading to lack of comprehensive assessment before scale up and adoption of emerging technologies. Utilizing the mechanistic models developed for engineering and biological systems with macroeconomic framework of Input-Output models, we propose a novel integrated approach to fully map the physical economy, that automates the process of mapping industrial flows and wastes in a region. The approach is demonstrated by mapping the agro-based physical economy of the state of Illinois, USA by using mechanistic models for 10 sectors, which have high impact on waste generation. Each model mechanistically simulates the material transformation processes in the economic sector and provides the material flow information for mapping. The model for physical economy developed in the form of a Physical Input-Output Table (PIOT) captures the interindustry physical interactions in the region and waste flows, thus providing insights into the opportunities to implement circular economy strategies i.e., adoption of recycling technologies at large scale. In Illinois, adoption of technologies for industrial waste-water & hog manure recycling will have the highest impact by reducing > 62 % of hog industry waste, > 99 % of soybean hull waste, and > 96 % of dry corn milling (corn ethanol production) waste reduction. Small % reduction in fertilizer manufacturing waste was also observed. The physical economy model revealed that Urea sector had the highest material use of 5.52E+08 tons and green bean farming with lowest material use of 1.30E+05 tons for the year modeled (2018). The mechanistic modeling also allowed to capture elemental flows across the physical economy with Urea sector using 8.25E+07 tons of carbon per operation-year (highest) and bean farming using 3.90E+04 tons of elemental carbon per operation-year (least). The approach proposed here establishes a connection between engineering and physical economy modeling community for standardizing the mapping of physical economy that can provide insights for successfully transitioning to a low carbon and zero waste circular economy. 

Life Cycle Analysis (LCA) has long been utilized for decision making about the sustainability of products. LCA provides information about the total emissions generated for a given functional unit of a product, which is utilized by industries or consumers for comparing two products with regards to environmental performance. However, many existing LCAs utilize data that is representative of an average system with regards to life cycle stage, thus providing an aggregate picture. It has been shown that regional variation may lead to large variation in the environmental impacts of a product, specifically dealing with energy consumption, related emissions and resource consumptions. Hence, improving the reliability of LCA results for decision making with regards to environmental performance needs regional models to be incorporated for building a life cycle inventory that is representative of the origin of products from a certain region. In this work, we present the integration of regionalized data from process systems models and other sources to build regional LCA models and quantify the spatial variations per unit of biodiesel produced in the state of Indiana for environmental impact. In order to include regional variation, we have incorporated information about plant capacity for producing biodiesel from North and Central Indiana. The LCA model built is a cradle-to-gate. Once the region-specific models are built, the data were utilized in SimaPro to integrate with upstream processes to perform a life cycle impact assessment (LCIA). We report the results per liter of biodiesel from northern and central Indiana facilities in this work. The impact categories studied were global warming potential (kg CO2 eq) and freshwater eutrophication (kg P eq). While there were a lot of variations at individual county level, both regions had a similar global warming potential impact and the northern region had relatively lower eutrophication impacts.