Assessing carbon dioxide emission reduction potentials of improved manufacturing processes using multiregional input output frameworks

Evaluating innovative process technologies has become highly important within the last decades. As standard tools different Life Cycle Assessment methods have been established, which are continuously improved. While those are designed for evaluating single processes they run into difficulties when it comes to assessing environmental impacts of process innovations at macroeconomic level. In this paper we develop a multi-step evaluation framework building on multi regional input–output data that allows estimating macroeconomic impacts of new process technologies, considering the network characteristics of the global economy. Our procedure is as follows: i) we measure differences in material usage of process alternatives, ii) we identify where the standard processes are located within economic networks and virtually replace those by innovative process technologies, iii) we account for changes within economic systems and evaluate impacts on emissions. Within this paper we exemplarily apply the methodology to two recently developed innovative technologies: longitudinal large diameter steel pipe welding and turning of high-temperature resistant materials. While we find the macroeconomic impacts of very specific process innovations to be small, its conclusions can significantly differ from traditional process based approaches. Furthermore, information gained from the methodology provides relevant additional insights for decision makers extending the picture gained from traditional process life cycle assessment.DFG, SFB 1026, Sustainable Manufacturing - Globale Wertschöpfung nachhaltig gestalte

Integrated Environmental Process Planning for the Design & Manufacture of Automotive Components

Advanced Product Quality Planning (APQP) logic is widely used by manufacturers for the design and manufacture of automotive components. Manufacturers are increasingly finding difficulties to incorporate environmental considerations in the broad range of products that they manufacture. Therefore, there is a need for a systematic method for environmental process planning to evaluate product configurations and their associated environmental impact. The framework and models discussed in this paper can deal with a variety of product characteristics and environmental impacts through a selection of Environmental Performance Indicators (EPIs) for a final product configuration. The framework and models have been applied in a real-life application and have proven that changes in product design or process selection can reduce the product's environmental impact and increase process efficiency. Hence, manufacturers can use the framework and models during the Advanced Product Quality Planning (APQP) process to benchmark each product variation that they manufacture in a standardised manner and realise cost saving opportunities

Dynamic cutting process modelling and its impact on the generation of surface topography and texture in nano/micro cutting

In the nano/micro cutting process, the surface quality is heavily dependent on all the dynamic factors, including those from the material, tooling, process parameters, servo accuracy, mechanical structural stiffness, and non-linear factors as well. The machined surface is generated based on the tool profile and the real tool path combining with the various external and internal disturbances. To bridge the gap between the cutting process and the surface topography/texture generation, an integrated simulation-based approach is presented involving the dynamic cutting process, control/drive system, and the surface generation. The simulations take account of all the intricate aspects of the cutting process resulting in the surface topography and texture formation, such as material heterogeneity, regenerative chatter, built-up edge (BUE), tool wear, spindle runout, environmental vibration, tool interference, etc. Both the frequency ratio method and sampling theoremare used to interpret the surface topography and texture formation. The effects of non-linear factors on the surface generation are simulated and analysed through the power spectral density (PSD) and significance on surface texture. The relationships among cutting force, tool path, and surface profile are discussed in detail. Furthermore, the proposed systematic modelling approach is verified by cutting trials, which provide the coincident results of the surface topography and areal power spectral density (APSD)

Energy efficiency in discrete-manufacturing systems: insights, trends, and control strategies

Since the depletion of fossil energy sources, rising energy prices, and governmental regulation restrictions, the current manufacturing industry is shifting towards more efficient and sustainable systems. This transformation has promoted the identification of energy saving opportunities and the development of new technologies and strategies oriented to improve the energy efficiency of such systems. This paper outlines and discusses most of the research reported during the last decade regarding energy efficiency in manufacturing systems, the current technologies and strategies to improve that efficiency, identifying and remarking those related to the design of management/control strategies. Based on this fact, this paper aims to provide a review of strategies for reducing energy consumption and optimizing the use of resources within a plant into the context of discrete manufacturing. The review performed concerning the current context of manufacturing systems, control systems implemented, and their transformation towards Industry 4.0 might be useful in both the academic and industrial dimension to identify trends and critical points and suggest further research lines.Peer ReviewedPreprin

Life cycle energy and carbon analysis of domestic combined heat and power generators

Micro Combined Heat and Power (micro-CHP) generators combine the benefits of the high-efficiency cogeneration technology and microgeneration and is being promoted as a means of lowering greenhouse gas emissions by decentralizing the power network. Life Cycle Assessment of energy systems is becoming a part of decision making in the energy industry, helping manufacturers promote their low carbon devices, and consumers choose the most environmentally friendly options. This report summarizes a preliminary life-cycle energy and carbon analysis of a wall-hung gas-powered domestic micro-CHP device that is commercially available across Europe. Combining a very efficient condensing boiler with a Stirling engine, the device can deliver enough heat to cover the needs of a typical household (up to 24kW) while generating power (up to 1kW) that can be used locally or sold to the grid. Assuming an annual heat production of 20 MWh, the study has calculated the total embodied energy and carbon emissions over a 15 years operational lifetime at 1606 GJ and 90 tonnes of CO2 respectively. Assuming that such a micro CHP device replaces the most efficient gas-powered condensing boiler for domestic heat production, and the power generated substitutes electricity from the grid, the potential energy and carbon savings are around 5000 MJ/year and 530 kg CO2/year respectively. This implies a payback period of the embodied energy and carbon at 1.32 - 2.32 and 0.75 - 1.35 years respectively. Apart from the embodied energy and carbon and the respective savings, additional key outcomes of the study are the evaluation of the energy intensive phases of the device’s life cycle and the exploration of potential improvements