Energy Efficient Manufacturing

Over the last several years, manufacturers have expressed increasing interest in reducing their energy consumption and have begun to search for opportunities to reduce their energy usage. In this book, the authors explore a variety of opportunities to reduce the energy footprint of manufacturing. These opportunities cover the entire spatial scale of the manufacturing enterprise: from unit process-oriented approaches to enterprise-level strategies. Each chapter examines some aspect of this spatial scale, and discusses and describes the opportunities that exist at that level. Case studies demonstrate how the opportunity may be acted on with practical guidance on how to respond to these opportunities.

This monograph presents a reliable methodology for characterising the energy and eco-efficiency of unit manufacturing processes. The Specific Energy Consumption, SEC, will be identified as the key indicator for the energy efficiency of unit processes. An empirical approach will be validated on different machine tools and manufacturing processes to depict the relationship between process parameters and energy consumptions. Statistical results and additional validation runs will corroborate the high level of accuracy in predicting the energy consumption. In relation to the eco-efficiency, the value and the associated environmental impacts of manufacturing processes will also be discussed. The interrelationship between process parameters, process value and the associated environmental impact will be integrated in the evaluation of eco-efficiency. The book concludes with a further investigation of the results in order to develop strategies for further efficiency improvement. The target audience primarily comprises researchers and experts in the field, but the book may also be beneficial for graduate students.

This book provides energy efficiency quantitative analysis and optimal methods for discrete manufacturing systems from the perspective of global optimization. In order to analyze and optimize energy efficiency for discrete manufacturing systems, it uses real-time access to energy consumption information and models of the energy consumption, and constructs an energy efficiency quantitative index system. Based on the rough set and analytic hierarchy process, it also proposes a principal component quantitative analysis and a combined energy efficiency quantitative analysis. In turn, the book addresses the design and development of quantitative analysis systems. To save energy consumption on the basis of energy efficiency analysis, it presents several optimal control strategies, including one for single-machine equipment, an integrated approach based on RWA-MOPSO, and one for production energy efficiency based on a teaching and learning optimal algorithm. Given its scope, the book offers a valuable guide for students, teachers, engineers and researchers in the field of discrete manufacturing systems.

Energy efficiency represents a cost-effective and immediate strategy of a sustainable development. Due to substantial environmental and economic implications, a strong emphasis is put on the electrical energy requirements of machine tools for metalworking processes. The improvement of energy efficiency is however confronted with diverse barriers, which sustain an energy efficiency gap of unexploited potential. The deficiencies lie in the lack of information about the actual energy requirements of machine tools, a minimum energy reference to quantify improvement potential and the possible actions to improve the energy demand. Therefore, a comprehensive concept for energy performance management of machine tools is developed which guides the transition towards energy efficient machine tools. It is structured in four innovative concept modules, which are embedded into step-by-step workflow models. The capability of the performance management concept is demonstrated in an automotive manufacturing environment. The target audience primarily comprises researchers and practitioners challenged to enhance energy efficiency in manufacturing. The book may also be beneficial for graduate students who want to specialize in this field.

Energy consumption is of great interest to manufacturing companies. Beyond considering individual processes and machines, the perspective on process chains and factories as a whole holds major potentials for energy efficiency improvements. To exploit these potentials, dynamic interactions of different processes as well as auxiliary equipment (e.g. compressed air generation) need to be taken into account. In addition, planning and controlling manufacturing systems require balancing technical, economic and environmental objectives. Therefore, an innovative and comprehensive methodology – with a generic energy flow-oriented manufacturing simulation environment as a core element – is developed and embedded into a step-by-step application cycle. The concept is applied in its entirety to a wide range of case studies such as aluminium die casting, weaving mills, and printed circuit board assembly in order to demonstrate the broad applicability and the benefits that can be achieved.

Over the last several years, manufacturers have expressed increasing interest in reducing their energy consumption and have begun to search for opportunities to reduce their energy usage. In this book, the authors explore a variety of opportunities to reduce the energy footprint of manufacturing. These opportunities cover the entire spatial scale of the manufacturing enterprise: from unit process-oriented approaches to enterprise-level strategies. Each chapter examines some aspect of this spatial scale, and discusses and describes the opportunities that exist at that level. Case studies demonstrate how the opportunity may be acted on with practical guidance on how to respond to these opportunities.

This book is presented to demonstrate how energy efficiency can be achieved in existing systems or in the design of a new system, as well as a guide for energy savings opportunities. Accordingly, the content of the book has been enriched with many examples applied in the industry. Thus, it is aimed to provide energy savings by successfully managing the energy in the readers’ own businesses. The authors primarily present the necessary measurement techniques and measurement tools to be used for energy saving, as well as how to evaluate the methods that can be used for improvements in systems. The book also provides information on how to calculate the investments to be made for these necessary improvements and the payback periods. The book covers topics such as: • Reducing unit production costs by ensuring the reduction of energy costs, • Efficient and quality energy use, • Meeting market needs while maintaining competitive conditions, • Ensuring the protection of the environment by reducing CO2 and CO emissions with energy saving and energy efficiency, • Ensuring the correct usage of systems by carrying out energy audits. In summary, this book explains how to effectively design energy systems and manage energy to increase energy savings. In addition, the study has been strengthened by giving some case studies and their results in the fields of intensive energy consumption in industry. This book is an ideal resource for practitioners, engineers, researchers, academics, employees and investors in the fields of energy, energy management, energy efficiency and energy saving.

The U.S. Department of Energy (DOE) has supported the Industrial Technologies Program (ITP) for more than a decade. This program supports R&D into energy efficiency technologies designed to decrease the energy intensity of the U.S. industrial sector. The focus in on seven energy-intensive industriesâ€"aluminum, chemicals, forest products, glass, metal casting, mining, and steelâ€"known as the Industries of the Future (IOF). DOE asked the NRC for a review of this program including an evaluation of the ITP strategic plan, an evaluation of the technical quality of individual subprogram plans, and the prospective value of the multi-year program plan. This report presents the results of that review. It contains an assessment of the ITP strategy, of how effective it is being implemented, and the likelihood of achieving program goals. It also provides conclusions about the quality of the subprograms and recommendations about how to strengthen the subprograms and the overall program.