Assessing the potential of yield improvements, through process scrap reduction, for energy and CO2 abatement in the steel and aluminium sectors

Targets to cut 2050 CO2 emissions in the steel and aluminium sectors by 50%, whilst demand is expected to double, cannot be met by energy efficiency measures alone, so options that reduce total demand for liquid metal production must also be considered. Such reductions could occur through reduced demand for final goods (for instance by life extension), reduced demand for material use in each product (for instance by lightweight design) or reduced demand for material to make existing products. The last option, improving the yield of manufacturing processes from liquid metal to final product, is attractive in being invisible to the final customer, but has had little attention to date. Accordingly this paper aims to provide an estimate of the potential to make existing products with less liquid metal production. Yield ratios have been measured for five case study products, through a series of detailed factory visits, along each supply chain. The results of these studies, presented on graphs of cumulative energy against yield, demonstrate how the embodied energy in final products may be up to 15 times greater than the energy required to make liquid metal, due to yield losses. A top-down evaluation of the global flows of steel and aluminium showed that 26% of liquid steel and 41% of liquid aluminium produced does not make it into final products, but is diverted as process scrap and recycled. Reducing scrap substitutes production by recycling and could reduce total energy use by 17% and 6% and total CO 2 emissions by 16% and 7% for the steel and aluminium industries respectively, using forming and fabrication energy values from the case studies. The abatement potential of process scrap elimination is similar in magnitude to worldwide implementation of best available standards of energy efficiency and demonstrates how decreasing the recycled content may sometimes result in emission reductions. Evidence from the case studies suggests that whilst most companies are aware of their own yield ratios, few, if any, are fully aware of cumulative losses along their whole supply chain. Addressing yield losses requires this awareness to motivate collaborative approaches to improvement. © 2011 Elsevier B.V. All rights reserved.

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.

The flow of steel into the construction sector

Half of the world's annual production of steel is used in constructing buildings and infrastructure. Producing this steel causes significant amounts of carbon dioxide to be released into the atmosphere. Climate change experts recommend this amount be halved by 2050; however steel demand is predicted to have doubled by this date. As process efficiency improvements will not reach the required 75% reduction in emissions per unit steel output, new methods must be examined to deliver service using less steel production. To apply such methods successfully to construction, it must first be known where steel is used currently within the industry. This information is not available so a methodology is proposed to estimate it from known data. Results are presented for steel flows by product for ten construction sectors for both the UK and the world in 2006. An estimate for steel use within a 'typical' building is also published for the first time. Industrial buildings and utility infrastructure are identified as the largest end-uses of steel, while superstructure is confirmed as the main use of steel in a building. The results highlight discrepancies in previous steel estimates and life-cycle assessments, and will inform future research on lowering demand for steel, hence reducing carbon emissions. © 2012 Elsevier B.V. All rights reserved.

Life cycle assessments of biodegradable, commercial biopolymers - A critical review

Biopolymers are generally considered an eco-friendly alternative to petrochemical polymers due to the renewable feedstock used to produce them and their biodegradability. However, the farming practices used to grow these feedstocks often carry significant environmental burdens, and the production energy can be higher than for petrochemical polymers. Life cycle assessments (LCAs) are available in the literature, which make comparisons between biopolymers and various petrochemical polymers, however the results can be very disparate. This review has therefore been undertaken, focusing on three biodegradable biopolymers, poly(lactic acid) (PLA), poly(hydroxyalkanoates) (PHAs), and starch-based polymers, in an attempt to determine the environmental impact of each in comparison to petrochemical polymers. Reasons are explored for the discrepancies between these published LCAs. The majority of studies focused only on the consumption of non-renewable energy and global warming potential and often found these biopolymers to be superior to petrochemically derived polymers. In contrast, studies which considered other environmental impact categories as well as those which were regional or product specific often found that this conclusion could not be drawn. Despite some unfavorable results for these biopolymers, the immature nature of these technologies needs to be taken into account as future optimization and improvements in process efficiencies are expected. © 2013 Elsevier B.V. All rights reserved.

Polymer film packaging for food: An environmental assessment

Plastics packaging is ubiquitous in the food industry, fulfilling a range of functions including a significant role in reducing food waste. The public perception of packaging, however, is dominated by end-of-life aspects, when the packaging becomes waste often found littering urban, rural and marine environments. A balanced analysis of the role of packaging demands that the whole lifecycle is examined, looking not only at the packaging itself but also at the product being packaged. This paper focuses on packaging in the meat and cheese industry, analysing the impact of films and bags. The functions of packaging are defined and the environmental impact of delivering these functions is assessed. The influence of packaging on levels of waste and energy consumption elsewhere in the system is examined, including the contentious issue of end-of-life for packaging. Strategies for minimizing the environmental impact of the packaging itself involve reduction in the amount of material used (thinner packaging), rather than emphasizing end-of-life issues. Currently, with polymer recycling not at a high level, evidence suggests that this strategy is justifiable. Biodegradable polymers may have some potential for improving environmental performance, but are still problematic. The conclusion is that although current packaging is in some ways wasteful and inefficient, the alternatives are even less desirable. © 2013 Elsevier B.V. All rights reserved.

Component level strategies for exploiting the lifespan of steel in products

Approximately 40% of annual demand for steel worldwide is used to replace products that have failed. With this percentage set to rise, extending the lifespan of steel in products presents a significant opportunity to reduce demand and thus decrease carbon dioxide emissions from steel production. This article presents a new, simplified framework with which to analyse product failure. When applied to the products that dominate steel use, this framework reveals that they are often replaced because a component/sub-assembly becomes degraded, inferior, unsuitable or worthless. In light of this, four products, which are representative of high steel content products in general, are analysed at the component level, determining steel mass and cost profiles over the lifespan of each product. The results show that the majority of the steel components are underexploited - still functioning when the product is discarded; in particular, the potential lifespan of the steel-rich structure is typically much greater than its actual lifespan. Twelve case studies, in which product or component life has been increased, are then presented. The resulting evidence is used to tailor life-extension strategies to each reason for product failure and to identify the economic motivations for implementing these strategies. The results suggest that a product template in which the long-lived structure accounts for a relatively high share of costs while short-lived components can be easily replaced (offering profit to the producer and enhanced utility to owners) encourages product life extension. © 2013 The Author.

An architecture design with data model for product recovery management systems

Due to concerns about environmental protection and resource utilization, product lifecycle management for end-of-life (EOL) has received increasing attention in many industrial sectors including manufacturing, maintenance/repair, and recycling/refurbishing of the product. To support these functions, crucial issues are studied to realize a product recovery management system (PRMS), including: (1) an architecture design for EOL services, such as remanufacturing and recycling; (2) a product data model required for EOL activity based on international standards; and (3) an infrastructure for information acquisition and mapping to product lifecycle information. The presented works are illustrated via a realistic scenario. © 2008 Elsevier B.V. All rights reserved.