A case study on the improvement of eco-efficiency ratios: application to a composite processing industry

The World Business Council for Sustainable Development (WBCSD) defines Eco-Efficiency as follows: ‘Eco- Efficiency is achieved by the delivery of competitively priced-goods and services that satisfy human needs and bring quality of life, while progressively reducing ecological impacts and resource intensity throughout the life-cycle to a level at least in line with the earth’s estimated carrying capacity’. Eco-Efficiency is under this point of view a key concept for sustainable development, bringing together economic and ecological progress. Measuring the Eco-Efficiency of a company, factory or business, is a complex process that involves the measurement and control of several and relevant parameters or indicators, globally applied to all companies in general, or specific according to the nature and specificities of the business itself. In this study, an attempt was made in order to measure and evaluate the eco-efficiency of a pultruded composite processing company. For this purpose the recommendations of WBCSD [1] and the directives of ISO 14301 standard [2] were followed and applied. The analysis was restricted to the main business branch of the company: the production and sale of standard GFRP pultrusion profiles. The main general indicators of eco-efficiency, as well as the specific indicators, were defined and determined according to ISO 14031 recommendations. With basis on indicators’ figures, the value profile, the environmental profile, and the pertinent eco-efficiency’s ratios were established and analyzed. In order to evaluate potential improvements on company eco-performance, new indicators values and ecoefficiency ratios were estimated taking into account the implementation of new proceedings and procedures, both in upstream and downstream of the production process, namely: a) Adoption of new heating system for pultrusion die in the manufacturing process, more effective and with minor heat losses; b) Implementation of new software for stock management (raw materials and final products) that minimize production failures and delivery delays to final consumer; c) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. In particular, the last approach seems to significantly improve the eco-efficient performance of the company. Currently, by-products and wastes generated in the manufacturing process of GFRP profiles are landfilled, with supplementary added costs to this company traduced by transport of scrap, landfill taxes and required test analysis to waste materials. However, mechanical recycling of GFRP waste materials, with reduction to powdered and fibrous particulates, constitutes a recycling process that can be easily attained on heavy-duty cutting mills. The posterior reuse of obtained recyclates, either into a close-looping process, as filler replacement of resin matrix of GFRP profiles, or as reinforcement of other composite materials produced by the company, will drive to both costs reduction in raw materials and landfill process, and minimization of waste landfill. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.

Improvement of Operational Efficiency effectiveness (OEE) using Six Sigma DMAIC Methodology — Case Bottomer line AD2378

Overall Equipment Effectiveness (OEE) is the key metric of operational excellence. OEE monitors the actual performance of equipment relative to its performance capabilities under optimal manufacturing conditions. It looks at the entire manufacturing environment measuring, in addition to the equipment availability, the production efficiency while the equipment is available to run products, as well as the efficiency loss that results from scrap, rework, and yield losses. The analysis of the OEE provides improvement opportunities for the operation. One of the tools used for OEE improvement is Six Sigma DMAIC methodology which is a set of practices originally developed to improve processes by eliminating defects. It asserts the continuous efforts to reduce variation in process outputs as key to business success, as well as the possibility of measurement, analysis, improvement and control of manufacturing and business processes. In the case of the Bottomer line AD2378 in Papsac Maghreb Casablanca plant, the OEE figures reached 48.65 %, which is below the accepted OEE group performance. This required immediate actions to achieve OEE improvement. This Master thesis focuses on the application of Six Sigma DMAIC methodology in the OEE improvement on the Bottomer Line AD2378 in Papsac Maghreb Casablanca plant. First, the Six Sigma DMAIC and OEE usage in operation measurement will be discussed. Afterwards, the different DMAIC phases will allow the identification of improvement focus, the identification of OEE low performance causes and the design of improvement solutions. These will be implemented to allow further tracking of improvement impact on the plant operations.

Improvement of Energy Efficiency in a Gold Mining Industry: Case Study of a Russian Gold Mining Company

The issue of energy efficiency is attracting more and more attention of academia, business and policy makers worldwide due to increasing environmental concerns, depletion of non-renewable energy resources and unstable energy prices. The significant importance of energy efficiency within gold mining industry is justified by considerable energy intensity of this industry as well as by the high share of energy costs in the total operational costs. In the context of increasing industrial energy consumption energy efficiency improvement may provide significant energy savings and reduction of CO2 emission that is highly important in order to contribute to the global goal of sustainability. The purpose of this research is to identify the ways of energy efficiency improvement relevant for a gold mining company. The study implements single holistic case study research strategy focused on a Russian gold mining company. The research involves comprehensive analysis of company’s energy performance including analysis of energy efficiency and energy management practices. This study provides following theoretical and managerial contributions. Firstly, it proposes a methodology for comparative analysis of energy performance of Russian and foreign gold mining companies. Secondly, this study provides comprehensive analysis of main energy efficiency challenges relevant for a Russian gold mining company. Finally, in order to overcome identified challenges this research conceives a guidance for a gold mining company for implementation of energy management system based on the ISO standard.

Characterization Of Process Efficiency Improvement In Laser Additive Manufacturing

Laser additive manufacturing (LAM), known also as 3D printing, has gained a lot of interest in past recent years within various industries, such as medical and aerospace industries. LAM enables fabrication of complex 3D geometries by melting metal powder layer by layer with laser beam. Research in laser additive manufacturing has been focused in development of new materials and new applications in past 10 years. Since this technology is on cutting edge, efficiency of manufacturing process is in center role of research of this industry. Aim of this thesis is to characterize methods for process efficiency improvements in laser additive manufacturing. The aim is also to clarify the effect of process parameters to the stability of the process and in microstructure of manufactured pieces. Experimental tests of this thesis were made with various process parameters and their effect on build pieces has been studied, when additive manufacturing was performed with a modified research machine representing EOSINT M-series and with EOS EOSINT M280. Material used was stainless steel 17-4 PH. Also, some of the methods for process efficiency improvements were tested. Literature review of this thesis presents basics of laser additive manufacturing, methods for improve the process efficiency and laser beam – material- interaction. It was observed that there are only few public studies about process efficiency of laser additive manufacturing of stainless steel. According to literature, it is possible to improve process efficiency with higher power lasers and thicker layer thicknesses. The process efficiency improvement is possible if the effect of process parameter changes in manufactured pieces is known. According to experiments carried out in this thesis, it was concluded that process parameters have major role in single track formation in laser additive manufacturing. Rough estimation equations were created to describe the effect of input parameters to output parameters. The experimental results showed that the WDA (width-depth-area of cross-sections of single track) is correlating exponentially with energy density input. The energy density input is combination of the input parameters of laser power, laser beam spot diameter and scan speed. The use of skin-core technique enables improvement of process efficiency as the core of the part is manufactured with higher laser power and thicker layer thickness and the skin with lower laser power and thinner layer thickness in order to maintain high resolution. In this technique the interface between skin and core must have overlapping in order to achieve full dense parts. It was also noticed in this thesis that keyhole can be formed in LAM process. It was noticed that the threshold intensity value of 106 W/cm2 was exceeded during the tests. This means that in these tests the keyhole formation was possible.

The investigation of energy efficiency measures in the traditional buildings in Oporto World Heritage Site

Background The improvement of energy efficiency in buildings is widely promoted as a measure to mitigate climate change through the reduction of CO2 emissions. Thermal regulations worldwide promote it, for both new and existing buildings. Among the existing stock, traditional and historic buildings pose the additional challenge of heritage conservation. Their energy efficiency upgrade raises the risk of provoking negative impacts on their significance. Aims and Methodology This research used an approach based on impact assessment methodologies, defining an inital baseline scenario for both heritage and energy, from which the appropriate improvement solutions were identified and assessed. The measures were dynamically simulated and the results for energy, CO2, cost and comfort compared with the initial scenario, and then being further assessed for their heritage impact to eventually determine the most feasible solutions. To test this method, ten case studies, representative of the identified typological variants, were selected among Oporto’s traditional buildings located in the World Heritage Site. Findings and Conclusions The fieldwork data revealed that the energy consumption of these dwellings was below the European average. Additionally, the households expressed that their home comfort sensation was overall positive. The simulations showed that the introduction of insulation and solar thermal panels were ineffective on these cases in terms of energy, cost and comfort. At the same time, these measures pose a great risk to the buildings heritage value. The most efficient solutions were obtained from behavioural changes and DHW retrofit. The study reinforced the idea that traditional buildings performed better than expected and can be retrofitted and updated at a low-cost and with passive solutions. The use of insulation and solar panels should be disregarded.

Ydinvoimalaitoksen höyryturbiinin suorituskyvyn laskenta

Diplomityön tavoitteena on selvittää Loviisan ydinvoimalaitoksen höyryturbiinin hyötysuhteen parantamismahdollisuuksia. Työn kuvaan liittyvät oleellisesti höyryturbiinin siipivyöhykkeiden nopeuskolmioiden sekä hyötysuhteiden laskenta. Höyryturbiinien kehityskaarta sekä turbiinin häviökerrointen laskentayhtälöitä on esitetty useasta eri lähteestä ja vuosikymmeniltä. Työssä selvitettiin uusimpia ydinvoimalaitosten kostea höyryturbiinien suunnitteluperusteita lukuisista eri lähteistä. Kaikkien lähteiden mukaan kostean höyryn alueella tapahtuvaa paisuntaa on haasteellista mallintaa. Työssä on esitelty artikkeleissa tulleita eri näkökulmia höyryturbiinien suorituskyvyn parantamiseksi, sekä rakenteellisia että laskennallisia. Työssä esitellään monia turbiinin virtauksen ja suorituskyvyn laskentamenetelmiä. Esimerkiksi Baumannin säännön laskenta on yksinkertainen tapa käsitellä turbiinin suorituskykyä kostean höyryn alueella. Keskeisimpiä tehtyjä havaintoja oli se, että korkeapaineturbiinin ensimmäisestä vaiheesta löytyi mahdollista parannuspotentiaalia Loviisaan ydinvoimalaitoksen tehon lisäämiseksi. Ensimmäisessä vaiheessa on oletettu siipien olevan Laval –tyyppisiä, mutta käytännössä näin ei ole. Korkeapaineturbiinin nykyisen turbosuuttimen toimintaa voitaisiin tehostaa. Lisäksi Loviisan matalapaineturbiinin viimeisen siipivaiheen jälkeen aiheutuu suuret ulosvirtaushäviöt. Osa suurinopeuksisen virtauksen energiasta pystyttäisiin kuitenkin hyödyntämään vielä ulosvirtauskanavassa olevalla diffuusorilla.

A computable general equilibrium analysis of the relative price sensitivity required to induce rebound effects in response to an improvement in energy efficiency in the UK economy

In recent years there has been extensive debate in the energy economics and policy literature on the likely impacts of improvements in energy efficiency. This debate has focussed on the notion of rebound effects. Rebound effects occur when improvements in energy efficiency actually stimulate the direct and indirect demand for energy in production and/or consumption. This phenomenon occurs through the impact of the increased efficiency on the effective, or implicit, price of energy. If demand is stimulated in this way, the anticipated reduction in energy use, and the consequent environmental benefits, will be partially or possibly even more than wholly (in the case of ‘backfire’ effects) offset. A recent report published by the UK House of Lords identifies rebound effects as a plausible explanation as to why recent improvements in energy efficiency in the UK have not translated to reductions in energy demand at the macroeconomic level, but calls for empirical investigation of the factors that govern the extent of such effects. Undoubtedly the single most important conclusion of recent analysis in the UK, led by the UK Energy Research Centre (UKERC) is that the extent of rebound and backfire effects is always and everywhere an empirical issue. It is simply not possible to determine the degree of rebound and backfire from theoretical considerations alone, notwithstanding the claims of some contributors to the debate. In particular, theoretical analysis cannot rule out backfire. Nor, strictly, can theoretical considerations alone rule out the other limiting case, of zero rebound, that a narrow engineering approach would imply. In this paper we use a computable general equilibrium (CGE) framework to investigate the conditions under which rebound effects may occur in the Scottish regional and UK national economies. Previous work has suggested that rebound effects will occur even where key elasticities of substitution in production are set close to zero. Here, we carry out a systematic sensitivity analysis, where we gradually introduce relative price sensitivity into the system, focusing in particular on elasticities of substitution in production and trade parameters, in order to determine conditions under which rebound effects become a likely outcome. We find that, while there is positive pressure for rebound effects even where (direct and indirect) demand for energy is very price inelastic, this may be partially or wholly offset by negative income and disinvestment effects, which also occur in response to falling energy prices.

Color tunability in green, red and infra-red upconversion emission in Tm3+/Yb3+/Ho3+ co-doped CeO2 with potential application for improvement of efficiency in solar cells

The preparation of Tm3+/Yb3+/Ho3+ co-doped CeO2 prepared by the precipitation method using ammonium hydroxide as a precursor is presented. By X-ray diffraction the materials show the phase-type of fluorite structure and the crystallite sizes were calculated by the Scherrer's equation. No other phase was observed evincing that the rare earth ions were inserted into the fluorite phase as substitutional or interstitial dopants. The microstrain calculated by the Williamson-Hall method do not show significant changes in their values, indicating that the inclusion of rare earths does not causes structural changes in the CeO2 used as a host matrix. All material showed intense upconversion emission at red and green region under excitation with diode laser at 980 nm. The color of emission changes from green to red with increasing excitation power pump. The materials showed suitable photoluminescent properties for applications as a laser source, solar cells, and great emitter at 800 nm. (C) 2014 Elsevier B.V. All rights reserved.

Efficiency improvement of HF communications using cognitive radio principles

Cognitive Radio principles can be applied to HF communications to make a more efficient use of the extremely scarce spectrum. In this contribution we focus on analyzing the usage of the available channels done by the legacy users, which are regarded as primary users since they are allowed to transmit without resorting any smart procedure, and consider the possibilities for our stations -over the HFDVL (HF Data+Voice Link) architecture- to participate as secondary users. Our goal is to enhance an efficient use of the HF band by detecting the presence of uncoordinated primary users and avoiding collisions with them while transmitting in different HF channels using our broad-band HF transceiver. A model of the primary user activity dynamics in the HF band is developed in this work. It is based on Hidden Markov Models (HMM) which are a powerful tool for modelling stochastic random processes, and is trained with real measurements from the 14 MHz band.

Efficiency improvement of non-uniformly-aged PV arrays

The utilization of solar energy by photovoltaic (PV) systems have received much research and development (R&D) attention across the globe. In the past decades, a large number of PV array have been installed. Since the installed PV arrays often operate in harsh environments, non-uniform aging can occur and impact adversely on the performance of PV systems, especially in the middle and late periods of their service life. Due to the high cost of replacing aged PV modules by new modules, it is appealing to improve energy efficiency of aged PV systems. For this purpose, this paper presents a PV module reconfiguration strategy to achieve the maximum power generation from non-uniformly aged PV arrays without significant investment. The proposed reconfiguration strategy is based on the cell-unit structure of PV modules, the operating voltage limit of gird-connected converter, and the resulted bucket-effect of the maximum short circuit current. The objectives are to analyze all the potential reorganization options of the PV modules, find the maximum power point and express it in a proposition. This proposition is further developed into a novel implementable algorithm to calculate the maximum power generation and the corresponding reconfiguration of the PV modules. The immediate benefits from this reconfiguration are the increased total power output and maximum power point voltage information for global maximum power point tracking (MPPT). A PV array simulation model is used to illustrate the proposed method under three different cases. Furthermore, an experimental rig is built to verify the effectiveness of the proposed method. The proposed method will open an effective approach for condition-based maintenance of emerging aging PV arrays.

Efficiency and power density improvement of grid-connected hybrid renewable energy systems utilizing high frequency-based power converters

High efficiency of power converters placed between renewable energy sources and the utility grid is required to maximize the utilization of these sources. Power quality is another aspect that requires large passive elements (inductors, capacitors) to be placed between these sources and the grid. The main objective is to develop higher-level high frequency-based power converter system (HFPCS) that optimizes the use of hybrid renewable power injected into the power grid. The HFPCS provides high efficiency, reduced size of passive components, higher levels of power density realization, lower harmonic distortion, higher reliability, and lower cost. The dynamic modeling for each part in this system is developed, simulated and tested. The steady-state performance of the grid-connected hybrid power system with battery storage is analyzed. Various types of simulations were performed and a number of algorithms were developed and tested to verify the effectiveness of the power conversion topologies. A modified hysteresis-control strategy for the rectifier and the battery charging/discharging system was developed and implemented. A voltage oriented control (VOC) scheme was developed to control the energy injected into the grid. The developed HFPCS was compared experimentally with other currently available power converters. The developed HFPCS was employed inside a microgrid system infrastructure, connecting it to the power grid to verify its power transfer capabilities and grid connectivity. Grid connectivity tests verified these power transfer capabilities of the developed converter in addition to its ability of serving the load in a shared manner. In order to investigate the performance of the developed system, an experimental setup for the HF-based hybrid generation system was constructed. We designed a board containing a digital signal processor chip on which the developed control system was embedded. The board was fabricated and experimentally tested. The system's high precision requirements were verified. Each component of the system was built and tested separately, and then the whole system was connected and tested. The simulation and experimental results confirm the effectiveness of the developed converter system for grid-connected hybrid renewable energy systems as well as for hybrid electric vehicles and other industrial applications.

Sustainability Improvement of a composite materials’ industry through recycling and re-engineering process approaches

Recent Advances in Mechanics and Materials in Design

Strength improvement of adhesively-bonded scarf repairs in aluminium structures with external reinforcements

Adhesively bonded techniques are an attractive option to repair aluminium structures, compared to more traditional methods. Actually, as a result of the improvement in the mechanical characteristics of adhesives, adhesive bonding has progressively replaced the traditional joining methods. There are several bonded repair configurations, as single-strap, double-strap and scarf. Compared with strap repairs, scarf repairs have the advantages of a higher efficiency and the absence of aerodynamic disturbance. The higher efficiency is caused by the elimination of the significant joint eccentricities of strap repairs. Moreover, stress distributions along the bond length are more uniform, due to tapering of the scarf edges. The main disadvantages of this technique are the difficult machining of the surfaces, associated costs and requirement of specialised labour. This work reports on an experimental and numerical study of the tensile behaviour of two-dimensional (2D) scarf repairs of aluminium structures bonded with the ductile epoxy adhesive Araldite® 2015. The numerical analysis, by Finite Elements (FE), was performed in Abaqus® and used cohesive zone models (CZM) for the simulation of damage onset and growth in the adhesive layer, thus enabling the strength prediction of the repairs. A parametric study was performed on the scarf angle (α) and different configurations of external reinforcement (applied on one or two sides of the repair, and also different reinforcement lengths). The obtained results allowed the establishment of design guidelines for repairing, showing that the use of external reinforcements enables increasing α for equal strength recovery, which makes the repair procedure easier. The numerical technique was accurate in predicting the repairs’ strength, enabling its use for design and optimisation purposes.