The increasing pressure on material availability, energy prices as well as emerging environmental legislation is leading manufacturers to adopt solutions to reduce their material and energy consumption as well as their carbon footprint, thereby becoming more sustainable. Ultimately manufacturers could potentially become zero carbon by having zero net energy demand and zero waste across the supply chain. Literature on zero carbon manufacturing, and the technologies that underpin it, is growing but there is little available on how a manufacturer undertakes the transition. Additionally, the work in this area is fragmented and clustered around technologies rather than around processes that link the technologies together. There is a need to better understand material, energy and waste process flows in a manufacturing facility from a holistic viewpoint. With knowledge of the potential flows, design methodologies can be developed to enable zero carbon manufacturing facility creation. This paper explores the challenges faced when attempting to design a zero carbon manufacturing facility. A broad scope is adopted from legislation to technology and from low waste to consuming waste. A generic material, energy and waste flow model is developed and presented to show the material, energy and waste inputs and outputs for the manufacturing system and the supporting facility and, importantly, how they can potentially interact. Finally the application of the flow model in industrial applications is demonstrated to select appropriate technologies and configure them in an integrated way.

Double‐base propellants consisting of nitrocellulose, nitroglycerin and stabilizer undergo chemical and physical changes upon aging, leading to changes in ballistic power and presenting explosive hazards. During aging, PTFE seals of the glass ampoules used in the aging studies undergo a yellow discoloration. This report studies the discoloration of the liners using desorption electrospray ionization (DESI), a gentle surface analysis technique based on electrospray ionization. The color bodies in the PTFE liners were identified by DESI together with tandem mass spectrometry to be the nitrated derivatives of the diphenylamine stabilizer: dinitro‐, trinitro‐, and tetranitrodiphenylamine. While increased nitration decreases vapor pressure of the DPA species, an increase in solubility in the PTFE liners occurs. This may account for these species not previously being observed during early aging studies as they are preferentially absorbed into the liners, which were not extracted prior to high performance liquid‐ chromatography analysis.

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