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Significant increases in industry energy efficiency are crucial for the transformation of the world's energy systems. Many production sites offer high energy savings capabilities, and if these are accompanied by short periods of economic amortization, companies should be willing to act. This case study provides a novel and extended energy assessment for plastics processing plants including primary energy, greenhouse gas emissions, and energy costs. The research distinguishes between the standard form of separate individual energy assessments and provides a more innovative holistic approach taking all relevant energy flows within the production system into account. Dynamic simulation offers a quick and effective way to predict the results of the possible energy saving measures highlighted in this analysis. The paper presents validated energy consumption simulations based on realistic processing conditions for two injection molding factories in different climatic zones. The results show that combining a number of separate energy saving measures can reduce the primary energy demand by around 26% for a German plant under temperate climate conditions and 20% for a Western Australian plant under Mediterranean conditions. However, when the separate energy saving measures are holistically combined the reduction in energy use significantly increases to 41% and 43% respectively. This holistic energy strategy involves incorporating better cogeneration and waste heat recovery options. For small and medium sized companies in particular major energy infrastructure investments may often be considered too expensive without examining the extended benefits from a holistic energy assessment perspective. In contrast, a holistic framework, like the one suggested in this paper could provide a number of new options for increasing energy efficiency that individually might normally not be accepted under conventional economic rate of return analysis. [ABSTRACT FROM AUTHOR]

Reducing energy demand in manufacture is an urgent challenge. This challenge is driven by higher consumer demand for manufactured products, increasing electricity and energy prices, volatility and uncertainty in energy supply and national policy. These factors, together with a need to reduce energy consumption derived carbon dioxide emissions, strategically call for energy efficient manufacturing. In manufacturing processes, especially mechanical machining, more than 90% of environmental impact arises from direct electrical energy demand in machine tools. At the machine tool level, the biggest share of the electrical energy associated with mechanical machining is required to bring the machine to a ready state and support non-cutting operations such as spindle torque requirements, auxiliary units and movements. These activities are controlled and related to machine commands such as NC codes. In this paper comprehensive information on energy intensity in machining process, including the influence of tool wear, was studied. Key energy states were identified to build up an energy demand for machining components. The paper defines the essential power constants for a database that can assist energy prediction for any available machines and workpiece materials. The assessment of alternative toolpaths identified major opportunities for energy demand reduction. [ABSTRACT FROM AUTHOR]

Abstract: A key factor deciding the capacity to increase the sustainability of final products is the energy efficiency. The energy embodied in a product is an aggregation of all of the energy embodied in the products' components and subsystems, expended through its manufacturing processes and logistical activities. Currently, accurate estimation of this energy metric is hindered due to the unavailability of energy use data traceable to individual processes and equipment associated with the product's assembly. In this paper, we propose using minimally-required energy to compute energy efficiency of a product assembly process. Based on the proposed approach, efficiency metrics established on the process, product, material and equipment characteristics have been presented at the assembly activity and equipment level. A case study has been presented for a hybrid laser welding process to demonstrate the computational methods used to arrive at these efficiency metrics. Major contributions of this paper are the metrics development and exemplifying the metrics through an actual assembly process (hybrid laser welding) case study. We will explain how these metrics can provide industries with a capability to identify opportunities to improve their sustainability performance across their assembly processes. [Copyright &y& Elsevier]

Abstract: This paper presents an analysis of Selective Laser Sintering (SLS) from an energy standpoint. Selective Laser Sintering (SLS) has a potential as an environmental benign alternative to traditional processes but only few authors deal with the process optimisation including energy aspects. In the present paper an analysis of the energetic aspect of SLS is proposed. In addition, with respect to the classical technological parameters (resolution, productivity) attention is paid to energetic elements (energetic productivity, laser parameters) showing how the perspective of a sensible development of such a kind of technology could be beneficial not only from a technological point of view, but also for energy saving in a lot of manufacturing fields. A polyamide powder is the material tested to acquire some characteristics data of the process. It is shown that the Volumetric Energy Intensity (VEI) of the process in optimal condition could be of the order of 0.2J for each mm3 of material agglomerated. [ABSTRACT FROM AUTHOR]

Abstract: This article provides an introduction to this Special Issue of Journal of Cleaner Production (JCLP), which contains thirteen, carefully selected articles from the 12th Conference, “Process Integration, Modelling and Optimisation for Energy Saving and Pollution Reduction” – PRES''09. This issue builds upon the multi-year co-operation between the PRES conference planners and the JCLP. The articles cover important subjects of increased efficiency in energy generation and usage and in improvements in industrial process optimisation. The first group of five papers focuses upon recent advances in emissions reduction and the resulting energy penalties. The second group of four papers deals with improving the efficiency and reliability in the utilisation of renewable energy, where hydrogen and biodiesel are the key energy carriers. The final group of three papers focus on process integration challenges of sustainable energy systems and upon the challenges of industrial/societal integration of sustainable energy systems into regional sustainable development planning. [Copyright &y& Elsevier]

The granite production chain is high energy and water intensive with low resource efficiency. This paper focus on characterizing the potential for environmental improvement of the granite production chain by promoting the optimization of sawing technology, the implementation of rainwater harvesting (RWH) and the material recovery of wasted granite (sludge). The environmental performance of multi-blade gangsaw (MBGS) and diamond multi-wire saw (DMWS) technologies is compared by mean of life cycle assessment. Results demonstrate that DMWS technology contribute 30% of water savings, 40% of energy savings and 80% of material savings per square meter of polished granite tiles (60 x 40 x 2 cm) production. These resource savings contribute together to reduce the product's environmental footprint by 35% to 80%. The potential for RWH is analyzed using Plugrisost® simulation software based on system dynamics. RWH depends on the relationship between rainfall, catchment surface and tank size according to the industrial process’s water demand. The results demonstrate major potential to satisfy over 50% of the systemś daily water requirements using rainwater stored in rainwater tanks of varying capacity. RWH is a sustainable strategy for industrial water cycle management. A comprehensive review of literature reveals a range of technically feasible alternatives to promote material recovery of granite sludge. The ceramic industry is one promising industrial endpoint with which to avoid waste landfilling and contribute to mineral, energy and water savings. This by-product synergy could also serve as starting point for springboarding exchanges with other industrial agents, becoming a global extension of resource efficiency. [ABSTRACT FROM AUTHOR]

Abstract: Machining tasks are performed on machine tools with enormous amount of energy consumption in manufacturing system. Understanding and characterizing task-oriented energy consumption is significantly essential to explore the potential on energy-saving in production management. To achieve it, this paper proposes a modeling method of task-oriented energy consumption for machining manufacturing system. The energy consumption characteristics driven by task flow in machining manufacturing system are analyzed, which describes that energy consumption dynamically depends on the flexibility and variability of task flow in production processes. Based on the task-oriented energy consumption characteristics, an event graph methodology has been exploited to model the energy consumption driven by tasks in production processes of machining manufacturing system. The proposed modeling method is solved in Simulink simulation environment, and applied to select the flexible processes of tasks for optimizing energy consumption. The results show a valuable insight of energy consumption in machining manufacturing system so as to make robust decisions on the potential for improving energy efficiency. [Copyright &y& Elsevier]