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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: The cement sub-sector consumes approximately 12–15% of total industrial energy use. Therefore, a state of art review on the energy use and savings is necessary to identify energy wastage so that necessary measures could be implemented to reduce energy consumption in this sub-sector. In this paper energy use at different sections of cement industries, specific energy consumption, types of energy use, details of cement manufacturing processes, various energy savings measures were reviewed and presented. Various energy savings measures were critically analyzed considering amount of energy that can be saved along with the implementation cost. Amount of CO2 reduction has been presented along with the payback period for different energy savings measures as well. This study complied a comprehensive literature on the cement industries in terms of Thesis (MS and PhD), peer reviewed journals papers, conference proceedings, books, reports, websites. It has been observed that China producing major share of global cement production. Coal contribute major share of fuel used in cement industries. However, along with conventional fuels, industries are moving towards the use of alternative fuels to reduce environmental pollution. It was reported that cement industries are moving from wet process to dry process as it consume less energy compared to wet process. [Copyright &y& Elsevier]

Characterizing and modeling the energy consumption of machining processes has been recognized as an effective measure to improve the energy efficiency of the manufacturing process and to reduce carbon emissions. Activities related to machine tools and operators in machining processes result in energy consumption and carbon emissions. However, energy evaluation for the activities related to operators has often been ignored in the energy modeling of machining processes, due to its complexity and variability. Consequently, energy-saving strategies developed without considering the energy consumption of operators are not optimal. To bridge this gap, this paper develops an energy consumption evaluation method for the activities related to machine tools and operators, and establishes a novel energy model of machine-operator systems to assess the energy efficiency of machining processes. The research results provide a promising method to identify new energy-saving potentials of machine-operator systems. The recommended energy-saving strategy regarding this method is different to traditional strategies, but with it a better energy-saving effect can be achieved. Finally, a case study of energy modeling and analysis for a CK6153 i CNC machine-operator system is examined, showing an energy-saving potential of 15.85% and illustrating the effectiveness of the proposed method. [ABSTRACT FROM AUTHOR]

The imbalance between energy supply and demand is expected to keep increasing, with the manufacturing sector being responsible for about one-third of world energy consumption. Hence, concerns about energy-efficient and environmentally benign manufacturing process have become an emerging issue. This paper suggests a novel hierarchy of energy saving technologies for machine tools, mainly for machining. Cutting is a widely used traditional process, and accounts for a large portion of energy consumption in machine tool sectors. A novel hierarchy is suggested, from the perspective of a single device manager, in accordance with the level of application. Technologies and strategies were compiled from research project reports, journal and conference articles, energy policies, etc . They were then rearranged in respective levels in the suggested hierarchy. Theories and technologies in the assessment and modeling of energy characteristics were reviewed, and general strategies on micro process planning were discussed at the software-based optimization level. Then, technologies for control and cutting improvement, such as novel lubrication and assisted machining systems, were introduced, and their effects were presented. Finally, improvement of hardware components and design rules for the environment were reviewed. Future market demands have clearly drawn more attention to energy efficiency, and the energy consumption of machine tools should be more accurately modeled and controlled. Loss and unnecessary operation of partial components should be minimized. From the perspective of energy efficiency, machine tools are expected to become more compact and lightweight. Operators and manufacturers need to understand both the process and hardware for greener machine tools. [ABSTRACT FROM AUTHOR]

• An energy-oriented selective maintenance policy (ESMP) is developed. • ESMP policy is applied to series–parallel multi-unit systems under sustainable manufacturing. • Preventive maintenance and preventive replacement can be optimized comprehensively. • Optimal maintenance schemes are obtained under limited maintenance resources. • ESMP policy achieves a significant improvement of energy efficiency in batch production. With the industry sustainable development and increasing awareness of energy conservation, many manufacturing enterprises prefer to develop the operation and maintenance (O&M) with high production throughput and low energy consumption. In reality, many manufacturing systems are required to conduct a sequence of predefined missions with finite breaks between any two consecutive missions. To successfully complete the next mission production, maintenance actions are arranged and performed on machines during each scheduled break. In this paper, an energy-oriented selective maintenance policy (ESMP) for series–parallel systems is investigated. At each break, multiple maintenance actions with different impacts on machine degradation are available under limited maintenance resources. To obtain the throughput-and-energy based maintenance scheme, we first model the system energy efficiency based on system throughput and energy consumption. Then, we integer the energy efficiency modeling, production throughout analysis, and selective maintenance scheduling into an optimization model. And the model objective is to find the appropriate maintenance action for each machine at each break subject to cost and duration constraints. Numerical examples have been addressed to demonstrate the performance and adaptability of our proposed ESMP in long-term selective maintenance scheduling. Finally, a comparative analysis with traditional reliability-oriented policy shows the significant improvement of energy efficiency. [ABSTRACT FROM AUTHOR]

Abstract: Energy efficiency and savings strategies in the combustion based industrial process heating has been reviewed comprehensively and presented in this paper. This work compiles latest literatures in terms of thesis, journal articles, conference proceedings, web materials, reports, books, handbooks on industrial process heating systems in the industrial sector. Different types of equipment used (i.e., recuperator, regenerators, heat wheels, heat pipes, economizers, etc.) and energy savings are reviewed in various industrial processes heating. Based on the review results, it is found that significant amounts of energy could be saved by using heat recovery system in the industrial process heating. By using recuperator up to 25% energy can be saved in the furnace. In the case of boiler, by using economizers 10% to 20% energy can be saved. Economic analysis shows that the payback period of recuperator and economizer are normally less than 2 years. It is also found that the payback period is lower when operating hour is comparatively high. [Copyright &y& Elsevier]

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]

Abstract: Industrial processes are the most energy consuming processes in the world. Modification of these processes helps us with controlling the consumption of energy and minimizing energy loss. Changing raw materials is one of the ways through which we can optimize industrial processes. In this paper, a new solvent mixture (furfural+a co-solvent) was used for the extraction of lubricating base oil from lube-oil cut. It was found that the energy consumption of the new solvent mixture for obtaining a product with the same quality was much lower than the original solvent. By using this new solvent mixture, the operating temperature of the top of tower was reduced by 30K. This leads to a high reduction in energy consumption in extraction of aromatics from lube oil. At our new extraction process by means of using new solvent mixture, the maximum energy saving was 38% per cubic meter of produced raffinate. [Copyright &y& Elsevier]

Abstract: This paper introduces the Quick-E-Scan methodology that has been developed to achieve the operational energy efficiency of small & medium enterprises (SMEs), characterized by being scarcely disposed to long energy audits and by a limited budget for energy management programs. On one side, through dividing the firm into functional units – either service (lighting, HVAC, etc.) or production units – the main consuming areas are identified and a criticality index is defined; conversely, an enhancement index highlights the gap of each unit towards the best available techniques (BATs) in energy management programs. Finally, a priority index, created with the junction of the two indexes, points out the most profitable areas in which energy saving measures should be implemented. The methodology, particularly quick and simple, has been successfully tested in 38 SMEs in Northern Italy. [Copyright &y& Elsevier]

Energy efficiency is an extremely important indicator for exploring energy conservation and consumption reduction. The traditional energy efficiency assessment methods for process industry lack an in-depth thinking on energy utilization of the whole system. Based on the proposed required energy, this paper established an energy efficiency assessment method for process industry. By establishing material and energy flow networks, energy efficiency of typical iron and steel manufacturing process (ISMP) is analyzed and its influencing factors are discussed. The results found that the required energy of coking, sintering, pelletizing, blast furnace iron-making, basic oxygen furnace steel-making and steel rolling are 2626.2 MJ/t-coke, 1122.9 MJ/t-sinter, 992.3 MJ/t-pellet, 9781.5 MJ/t-hot metal, 393.95 MJ/t-molten steel and 445.3 MJ/t-steel products, respectively. The energy efficiency of typical ISMP is 66.9%. The energy efficiency of the ISMP can be effectively improved by adjusting the steel ratio, recovering waste heat and residual energy, and developing interface technologies. • Energy efficiency assessment method of process industry is proposed and established. • The material and energy flow networks of iron and steel manufacturing process are established. • The required energy of iron and steel manufacturing process is analyzed and given. • Energy efficiency of typical iron and steel manufacturing process is evaluated and given. • The influencing factor of energy efficiency is discussed. [ABSTRACT FROM AUTHOR]