A global assessment of manufacturing: Economic development, energy use, carbon emissions, and the potential for energy efficiency and materials recycling

We present in two parts an assessment of global manufacturing. In the first part, we review economic development, pollution, and carbon emissions from a country perspective, tracking the rise of China and other developing countries. The results show not only a rise in the economic fortunes of the newly industrializing nations, but also a significant rise in global pollution, particularly air pollution and CO2 emissions largely from coal use, which alter and even reverse previous global trends. In the second part, we change perspective and quantitatively evaluate two important technical strategies to reduce pollution and carbon emissions: energy efficiency and materials recycling. We subdivide the manufacturing sector on the basis of the five major subsectors that dominate energy use and carbon emissions: (a) iron and steel, (b) cement, (c) plastics, (d) paper, and (e) aluminum. The analysis identifies technical constraints on these strategies, but by combined and aggressive action, industry should be able to balance increases in demand with these technical improvements. The result would be high but relatively flat energy use and carbon emissions. The review closes by demonstrating the consequences of extrapolating trends in production and carbon emissions and suggesting two options for further environmental improvements, materials efficiency, and demand reduction. © 2013 by Annual Reviews. All rights reserved.

The environmental and economic sustainability of potential bioethanol from willow in the UK.

Life cycle assessment has been used to investigate the environmental and economic sustainability of a potential operation in the UK in which bioethanol is produced from the hydrolysis and subsequent fermentation of coppice willow. If the willow were grown on idle arable land in the UK, or, indeed, in Eastern Europe and imported as wood chips into the UK, it was found that savings of greenhouse gas emissions of 70-90%, when compared to fossil-derived gasoline on an energy basis, would be possible. The process would be energetically self-sufficient, as the co-products, e.g. lignin and unfermented sugars, could be used to produce the process heat and electricity, with surplus electricity being exported to the National Grid. Despite the environmental benefits, the economic viability is doubtful at present. However, the cost of production could be reduced significantly if the willow were altered by breeding to improve its suitability for hydrolysis and fermentation.

Mixing ventilation can reduce energy costs

The article provides information on a study on the potential of mixing ventilation in reducing energy costs in buildings such as theaters and schools. The study found that neither Manchester’s Contact Theatre and the Garrick Theatre in Lichfield in England is operating according to the displacement-ventilation principle upon which they were designed. Hybrid mixing ventilation has an important impact on both the ventilation rate and the thermal comfort of the theatres.

Optimisation of a piezoelectric system for energy harvesting from traffic vibrations

Piezoelectric systems are viewed as a promising approach to energy harvesting from environmental vibrations. The energy harvested from real vibration sources is usually difficult to estimate analytically. Therefore, it is hard to optimise the associated energy harvesting system. This work investigates the optimisation of a piezoelectric cantilever system using a genetic algorithm based approach with numerical simulations. The genetic algorithm globally considers the effects of each parameter to produce an optimal frequency response to scavenge more energy from the real vibrations while the conventional sinusoidal based method can only optimise the resistive load for a given resonant frequency. Experimental acceleration data from the vibrations of a vehicle-excited manhole cover demonstrates that the optimised harvester automatically selects the right frequency and also synchronously optimises the damper and the resistive load. This method shows great potential for optimizing the energy harvesting systems with real vibration data. ©2009 IEEE.

Investigation of the effect of combustor cooling geometry on acoustic energy absorption

To control combustion instabilities occurring in LPP gas turbine combustors, several active and passive systems have been developed in recent years. The combustion chamber cooling geometry has the potential to influence instability feedback loops by absorbing acoustical energy inside the combustor. The design of the cooling liner and the geometry of the cooling plenum and the cooling air flow rate have a significant influence on the absorption characteristics of the system. This paper presents the results of a cold flow study which was carried out in the course of a comprehensive study on the influence of the cooling geometry on combustor thermoacoustics. Absorption characteristics of three different cooling liner geometries and non-perforated plates were determined over a frequency range from 50 Hz to 600 Hz for different cooling flow rates and different cooling plenum volumes. The experimental results compared well with results from a low order thermoacoustic network model. The acoustic energy absorption spectrum of a cooling liner with 90°-hole configuration was found to be strongly dependent on cooling flow rate and cooling plenum volume, whereas the absorption spectrum of cooling liners with 25°-holes were found to be strongly dependent on the cooling plenum volume, but less dependent on the cooling air flow rate. All cooling liner setups with perforations were capable of increased acoustic absorption over a broad band of frequencies compared to the case of non-perforated combustor walls. © 2010 by Johannes Schmidt.

The technical potential for reducing metal requirements through lightweight product design

Metal production consumes around 10% of all global energy, so is a significant driver of climate change and other concerns about sustainability. Demand for metal is rising and forecast to double by 2050 through a combination of growing total demand from developing countries, and ongoing replacement demand in developed economies. Metal production is already extremely efficient, so the major opportunities for emissions abatement in the sector are likely to arise from material efficiency - using less new metal to meet demand for services. Therefore this paper examines the opportunity to reduce requirements for steel and aluminium by lightweight design. A set of general principles for lightweight design are proposed by way of a simple analytical example, and are then applied to five case study products which cumulatively account for 30% of global steel product output. It is shown that exploiting lightweight design opportunities for these five products alone could reduce global steel requirements by 5%, and similar savings in aluminium products could reduce global aluminium requirements by 7%. If similar savings to those in the design case studies were possible in all steel and aluminium products, total material requirements could be reduced by 25-30%. However, many of these light-weighting measures are, at present, economically unattractive, and may take many years to implement. © 2011 Elsevier B.V. All rights reserved.

Zero carbon manufacturing facility - Towards integrating material, energy, and waste process flows

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. The literature on zero carbon manufacturing and the technologies that underpin it are 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. © 2009 IMechE.

The role for low carbon electrification technologies in poverty reduction and climate change strategies: A focus on renewable energy mini-grids with case studies in Nepal, Peru and Kenya

As a potential poverty reduction and climate change strategy, this paper considers the advantages and disadvantages of using renewable energy technologies for rural electrification in developing countries. Although each case must be considered independently, given a reliable fuel source, renewable energy mini-grids powered by biomass gasifiers or micro-hydro plants appear to be the favoured option due to their lower levelised costs, provision of AC power, potential to provide a 24. h service and ability to host larger capacity systems that can power a wide range of electricity uses. Sustainability indicators are applied to three case studies in order to explore the extent to which sustainable welfare benefits can be created by renewable energy mini-grids. Policy work should focus on raising awareness about renewable energy mini-grids, improving institutional, technical and regulatory frameworks and developing innovative financing mechanisms to encourage private sector investments. Establishing joint technology and community engagement training centres should also be encouraged. © 2011 Elsevier Ltd.

The use of energy in China: Tracing the flow of energy from primary source to demand drivers

We present a map of the transformation of energy in China as a Sankey diagram. After a review of previous work, and a statement of methodology, our main work has been the identification, evaluation, and treatment of appropriate data sources. This data is used to construct the Sankey diagram, in which flows of energy are traced from energy sources through end-use conversion devices, passive systems and final services to demand drivers. The resulting diagram provides a convenient and clear snapshot of existing energy transformations in China which can usefully be compared with a similar global analysis and which emphasises the potential for improvements in energy efficiency in 'passive systems'. More broadly, it gives a basis for examining and communicating future energy scenarios, including changes to demand, changes to the supply mix, changes in efficiency and alternative provision of existing services. © 2012 Elsevier Ltd.

Managing water resources and their connection to land and energy

Effective management is a key to ensuring the current and future sustainability of land, water and energy resources. Identifying the complexities of such management is not an easy task, especially since past studies have focussed on studying these resources in isolation from one another. However, with rapid population growth and an increase in the awareness of a potential change in climatic conditions that may affect the demand for and supply of food, water and energy, there has been a growing need to integrate the planning decisions relating to these three resources. The paper shows the visualisation of linked resources by drawing a set of interconnected Sankey diagrams for energy, water and land. These track the changes from basic resource (e.g. coal, surface water, groundwater and cropland) through transformations (e.g. fuel refining and desalination) to final services (e.g. sustenance, hygiene and transportation). The focus here is on the water analysis aspects of the tool, which uses California as a detailed case study. The movement of water in California is traced from its source to its services by mapping the different transformations of water from when it becomes available, through its use, to further treatment, to final sinks (including recycling and reuse of that resource). The connections that water has with energy and land resources for the state of California are highlighted. This includes the amount of energy used to pump and treat water, and the amount of water used for energy production and the land resources which create a water demand to produce crops for food. By mapping water in this way, policy-makers and resource managers can more easily understand the competing uses of water (environment, agriculture and urban use) through the identification of the services it delivers (e.g. sanitation, agriculture, landscaping), the potential opportunities for improving the management of the resource (e.g. building new desalination plants, reducing the demand for services), and the connections with other resources which are often overlooked in a traditional sector-based management strategy.

The roles of energy and material efficiency in meeting steel industry CO2 targets.

Identifying strategies for reducing greenhouse gas emissions from steel production requires a comprehensive model of the sector but previous work has either failed to consider the whole supply chain or considered only a subset of possible abatement options. In this work, a global mass flow analysis is combined with process emissions intensities to allow forecasts of future steel sector emissions under all abatement options. Scenario analysis shows that global capacity for primary steel production is already near to a peak and that if sectoral emissions are to be reduced by 50% by 2050, the last required blast furnace will be built by 2020. Emissions reduction targets cannot be met by energy and emissions efficiency alone, but deploying material efficiency provides sufficient extra abatement potential.

Open cycle thorium–uranium-fuelled nuclear energy systems

The potential for countries that currently have a nominal nuclear energy infrastructure to adopt thorium–uranium-fuelled nuclear energy systems, using a once-through ‘open’ nuclear fuel cycle, has been suggested by the International Atomic Energy Agency. This review paper highlights generation II, III and III+ nuclear energy technologies that could potentially adopt an open thorium–uranium fuel cycle and qualitatively highlights the main differences between the open thorium–uranium and open uranium fuel cycles.

The potential use of 241Am as proliferation resistant burnable poison in PWRs

This paper discusses the use of 241Am as proliferation resistant burnable poison for light water reactors. Homogeneous addition of small (as little as 0.12%) amounts of 241Am to the conventional light water reactor fuel results in significant increase in 238Pu/Pu ratio in the discharged fuel improving its proliferation resistance. Moreover, 241Am, admixed to the fuel, acts as burnable absorber allowing for substantial reduction in conventional reactivity control means without a notable fuel cycle length penalty. This is possible due to favorable characteristics of 241Am transmutation chain. The fuel cycle length penalty of introducing 241Am into the core is evaluated and discussed, as well as the impact of He production in the fuel pins and degradation of reactivity feedback coefficients. Proliferation resistance and reactivity control features related to the use of 241Am are compared to those of using 237Np, which has also been suggested as an additive to the conventional fuel in order to improve its proliferation resistance. It was found that 241Am admixture is more favorable than 237Np admixture because of the smaller fuel cycle length penalty and higher burnable poison savings. Addition of either 237Np or 241Am would provide substantial but not ultimate protection from misuse of Pu originating in the spent fuel from the commercial power reactors. Therefore, the benefits from application of the concept would have to be carefully evaluated against the additional costs and proliferation risks associated with manufacturing of 237Np or 241Am doped fuel. Although this work concerns specifically with PWRs, the conclusions could also be applied to BWRs and, to some extent, to other thermal spectrum reactor types. © 2009 Elsevier Ltd. All rights reserved.

Engineering Fundamentals of Energy Efficiency

Using energy more efficiently is essential if carbon emissions are to be reduced. According to the International Energy Agency (IEA), energy efficiency improvements represent the largest and least costly savings in carbon emissions, even when compared with renewables, nuclear power and carbon capture and storage. Yet, how should future priorities be directed? Should efforts be focused on light bulbs or diesel engines, insulating houses or improving coal-fired power stations? Previous attempts to assess energy efficiency options provide a useful snapshot for directing short-term responses, but are limited to only known technologies developed under current economic conditions. Tomorrow's economic drivers are not easy to forecast, and new technical solutions often present in a disruptive manner. Fortunately, the theoretical and practical efficiency limits do not vary with time, allowing the uncertainty of economic forecasts to be avoided and the potential of yet to be discovered efficient designs to be captured. This research aims to provide a rational basis for assessing all future developments in energy efficiency. The global fow of energy through technical devices is traced from fuels to final services, and presented as an energy map to convey visually the scale of energy use. An important distinction is made between conversion devices, which upgrade energy into more useable forms, and passive systems, from which energy is lost as low temperature heat, in exchange for final services. Theoretical efficiency limits are calculated for conversion devices using exergy analysis, and show a 89% potential reduction in energy use. Efforts should be focused on improving the efficiency of, in relative order: biomass burners, refrigeration systems, gas burners and petrol engines. For passive systems, practical utilisation limits are calculated based on engineering models, and demonstrate energy savings of 73% are achievable. Significant gains are found in technical solutions that increase the thermal insulation of building fabrics and reduce the mass of vehicles. The result of this work is a consistent basis for comparing efficiency options, that can enable future technical research and energy policy to be directed towards the actions that will make the most difference.

Demonstration of cascaded operation of active-passive integrated 4×4 SOA switches with on-chip monitoring for power control and energy consumption optimization

Cascaded 4×4 SOA switches with on-chip power monitoring exhibit potential for lowpower 16×16 integrated switches. Cascaded operation at 10Gbit/s with an IPDR of 8.5dB and 79% lower power consumption than equivalent all-active switches is reported © 2013 OSA.