Green Engineering Systems · 2019. 3. 14. · Green Engineering Systems. UNIT-2: ENERGY EFFICIENT PROCESS SYLLABUS ... increase in the number of studies on environmentally conscious

University JNTU Kakinada

Regulation R 16

Year III Year

Semester II Semester

Teaching Classes 3+1

Credits 3

Name of the Faculty Singuru Rajesh

Unit V – Energy Efficient Process

SINGURU RAJESH DEPARTMENT OF MECHANICAL ENGINEEING SLIDE NUMBER 1

Green Engineering Systems

UNIT-2: ENERGY EFFICIENT PROCESS

SYLLABUS

• Environmental impact of the current manufacturing practices and systems, benefits of greenmanufacturing systems, selection of recyclable and environment friendly materials inmanufacturing, design and implementation of efficient and sustainable green production systemswith examples like environmental friendly machining, vegetable based cutting fluids, alternatecasting and joining techniques, zero waste manufacturing.


Industrial Energy Efficiency - Energy


ENERGY is defined scientifically as the capacity of a system to perform work.

In Industrial Energy Efficiency, ENERGY refers to the various forms of energy

source that can be purchased, stored, treated and used in equipment or in a process,

such as oil, coal, gas and electricity.

Energy uses include heating, cooling, production processes, transport and so on.

Over the past decade, climate change from Green House Gasses has moved from being a

topic of general discussion to becoming an important factor contributing to the financial

performance for manufacturing companies.

Environmental Impact on Current Manufacturing


Environmental issues are increasing popular among researchers, leading to a significant

increase in the number of studies on environmentally conscious product design and

manufacturing.

There is increasing concern about environmental issues in product design and support;

systematic frameworks need to be created and offered to designers.

Automated disassembly systems are widely studied, as a significant portion of the

current disassembly systems is based on manual labour; research is also required into

environmentally friendly disassembly.

Research on product design focuses on multi criteria techniques which allow the

simultaneous consideration of material requirements and economic, consumer and

environmental concerns.

Environmental Impact on Current Manufacturing


However, the environmental impact of product manufacturing and support are ignored.

We need environmentally conscious design, manufacturing and implementation

methodologies that integrate design and processes.

With increased environmental awareness in society, product manufacturers must

educate their engineers and technicians in environmental aspects of manufacturing to

increase their competitive edge.

In addition, environmentally conscious manufacturing and support principles should be

incorporated into engineering courses at universities.

Energy Efficient Process


Society’s rising concern

for Green can be grouped

into three broad

categories:

1. Rising emissions and

associated climate

change Greenhouse gas

(GHG) emissions

2. Fast depletion of scarce

natural resources

3. Growing waste

generation and pollution

Green Manufacturing


Green stands for ecological sustainability.

It includes in many concerns, but not limited to air, water and land pollution, energy

usage and efficiency, and waste generation and recycling.

Green initiatives aim to minimize the impact of human activities on the environment.

Forces Driving Green Manufacturing


A number of companies have started adopting Green initiatives as an integral part of their

operations. These initiatives are driven by five factors:

Rising energy and input costs

Growing consumer pull for Green products

Increasing regulatory pressures as policy makers introduce new and stricter environmental

and waste management laws

Technological advances which open up new attractive business opportunities

The need to enhance competitive differentiation, particularly for first movers or those who

are able to break the compromise between short–term higher costs and numerous benefits

(example: brand premium, new customer segments)

Green Engineering (Manufacturing) Guiding Principles


A designer must strive to

Engineer processes and products holistically, use systems analysis, and integrate environmental

impact assessment tools.

Conserve and improve natural ecosystems while protecting human health and well-being.

Use life-cycle thinking in all engineering activities.

Ensure that all material and energy inputs and outputs are as inherently safe and benign as

possible.

Minimize depletion of natural resources.

Strive to prevent waste.

Develop and apply engineering solutions, while being cognizant of local geography, aspirations,

and cultures.

Create engineering solutions beyond current or dominant technologies; improve, innovate, and

invent (technologies) to achieve sustainability.

Actively engage communities and stakeholders in development of engineering solutions.

Benefits of Green Manufacturing


Benefits of Green Manufacturing:

Reduction in harmful impact of manufacturing on the environment and ecosystem

Cost of energy is decreased by using solar and wind energy instead of energy generated by

fossil fuels

By implementing optimized procedures and automation for manufacturing reduction in the

waste generation

Quality of air, water in the premises of industry increases

Performances of workers increases with the increase in the health consciousness

Green Manufacturing


Green Manufacturing


Transformation to Green Manufacturing:

Manufacturing companies can address these concerns

by focussing on three areas:

Green energy

Green products

Green processes in business operations

Transformation to Green Manufacturing


Green energy

Green energy involves production and use of cleaner energy.

This is the first and most obvious step given the dependence of industry on energy.

Green energy includes both deploying renewable energy sources like CNG, wind,

solar and biomass, and achieving higher energy efficiency in operations.



Green products

In this developing greener products is the second step in this transformation.

‘Recycled’, ‘Low carbon footprint’, ‘Organic’ and ‘Natural’ are becoming popular buzz–

words which are associated with Green products.

Developing Green products can often mean higher costs.

By developing Green products that are sought by consumers and effectively marketing

them, companies can derive additional volumes and price premiums, which can offset

their cost of development.



Green products



Green processes in business operations:

The third area is implementing Green processes in operations.

This entails efficient use of key resources, reducing waste generation through lean

operations, bringing down the carbon foot–print and conserving water.

Employing Green processes improves operational efficiency and lowers costs.

Sustainable Product Development


Sustainable product development is the design and development of products that have a

minimal impact on the environment.

New types of raw material are being developed all the time as our understanding of

molecular structure and our ability to manipulate these structures improves.

Increasingly raw materials can be tailored to specific applications.

Sustainable Product Development


Sustainable product development






Basic Environmental Considerations

Selection criteria for Design

Reduce the amount of raw materials

Reduce the number of components

Reduce the products energy requirements

Increase the useful life cycle

Maximize the use of renewable and recyclable materials

Minimize the environmental impact over the entire life cycle of the product

Environmentally Conscious Manufacturing


Environmental consciousness and recycling regulations are putting pressure on both

manufacturers and consumers, forcing them to produce, use and dispose of products in a

responsible manner.

This has led to a need for models, algorithms and software to create new designs and

also to address the logistics involved in support and remanufacturing, recycling and

disassembly for an ever-increasing number of discarded products.

The current focus on environmental manufacturing and logistics is different from the

traditional focus on pollution control.

Products are now seen as interacting with the environment. Therefore, rather than looking

at a product in isolation, manufacturers need to adopt a cradle-to-grave approach and

consider the product life cycle support and requirements.

Environmentally Conscious Manufacturing


Environmentally conscious manufacturing consists of the following two key issues:

1) Understanding the life cycle of the product and its impact on the environment at each of

its life stages;

2) Making better decisions during product design, manufacturing and use so

environmental attributes of the product and manufacturing process are kept at a desired level.

In addition, understanding the operation and end-of-life stage of the product is critical as one

of the largest impacts on the environment occurs at this stages.

Product Life-cycle in Manufacturing


Product Stewardship


Product stewardship, this concept represents a systematic effort by manufacturers to

reduce the risks to human health and the environment over all segments of a product’s life cycle.

Product stewardship assures the following expectations of environmentally conscious

manufacturing are met:

Evaluation of product design, material selection and support for environmentally conscious

manufacturing.

Ease of maintenance and recycling.

Ease of support and disassembly.

Effectiveness of waste collection systems.

Safe disposal of hazardous wastes.

Environmental impact assessment of manufacturing and maintenance processes.

Economics of support and recycling.

Selection of Materials


The incorporation of environmental issues into the design and development stages of a product

is expressed in various terms:

Eco-design, design for reliability, design for maintainability, design for the environment,

green design, sustainable design, life-cycle design, re-design etc.

Although these concepts highlight different aspects of “green”, they all and, at the same time,

to maximize the use of resources. aim to minimize damage to the environment/human during

a product’s life cycle

Consequently, they lead to savings in energy and materials, while benefiting the environment.



• The selection of materials is affected by such factors as availability and cost, but reliability

and environmental issues are increasingly being added to the mix.

• A number of methodologies and tools have already been suggested by researchers to deal with

environmental issues at the design stage.

Material Selection Criteria in sustainability criteria involves

Useful life cycle

Overall Energy footprint

Module Design

Design for Reusability

Design for Disassembly

Separation Techniques

Ease of reuse and or recycling at the component or sub-assembly level.



Material: Wood, Bamboo, Cotton

Advantages:

Renewable

Light

durable and strong

can be machined or woven

inexpensive

mature understanding of design and

performance issues

Disadvantages:

low to high strength to weight ratio

increased material innovations

Sustainability:

decomposes easily

can be burnt

Material: Steel, Aluminium, Titanium

Advantages: -

durable and strong

can be plastics formed

inexpensive

high cost of machining

mature understanding of design and

performance issues

Disadvantages:

low strength to weight ratio

easily corrodes

limited material innovations

Sustainability:

mature reclamation infrastructure

separation technology is mature

easily re-melting

Example

Vegetable Based Cutting Fluids




A wide variety of cutting fluids are commercially available in the cutting fluid suppliers in

order to provide machining performances for a number of industries.

In machining, mineral, synthetic and semi-synthetic cutting fluids are widely used but,

recently, uses of vegetable based cutting fluids have been increased.

Although, these cutting fluids are beneficial in the industries, their uses are being questioned

nowadays as regards to health and environmental issues.

Cutting fluids are contaminated with metal particles and degradation products which diminish

the effectiveness of cutting fluids.



To minimize the adverse environmental effects associated with the use of cutting fluids, the

hazardous components from their formulations have to be eliminated or reduced to the

acceptable level.

In addition, mineral based cutting fluids are going to be replaced with vegetable based cutting

fluids since they are environmentally friendly.

Today to diminish the negative effects associated with cutting fluids, researchers have

developed new bio based cutting fluids from various vegetable oils.



Different Types of Vegetable oils can

used as Lubricant

Coconut oil,

palm oil-based,

jatropha oil

soybean oil,

sunflower oil,

karanja and neem oil,

canola oil, and mineral oils



Vegetable Based Cutting Fluids and

Lubricants

Recyclable Materials


Recycling is the process of converting waste materials into new materials and objects.

It is an alternative to "conventional" waste disposal that can save material and help lower

greenhouse gas emissions.

Recycling can prevent the waste of potentially useful materials and reduce the

consumption of fresh raw materials, thereby reducing: energy usage, air pollution (from

incineration), and water pollution (from landfilling).

Recycling aims at environmental sustainability by substituting raw material inputs into

and redirecting waste outputs out of the economic system.





Recyclable materials include many kinds of glass, paper, cardboard, metal, plastic, tires,

textiles, and electronics.

The composting or other reuse of biodegradable waste such as food or garden waste is also

considered recycling.

Materials to be recycled are either brought to a collection centre or picked up from the curb-

side, then sorted, cleaned, and reprocessed into new materials destined for manufacturing.

Recycling is a key component of modern waste reduction and is the third component of the

"Reduce, Reuse, and Recycle" waste hierarchy.

Recyclable Materials (Plastics)


Type 1 (polyethylene terephthalate) is commonly found in soft drink and water bottles.

Type 2 (high-density polyethylene) is found in most hard plastics such as milk jugs, laundry

detergent bottles, and some dishware.

Type 3 (polyvinyl chloride) includes items such as shampoo bottles, shower curtains, hula

hoops, credit cards, wire jacketing, medical equipment, siding, and piping.

Type 4 (low-density polyethylene) is found in shopping bags, squeezable bottles, tote bags,

clothing, furniture, and carpet.

Type 5 is polypropylene and makes up syrup bottles, straws, Tupperware, and some automotive

parts.

Type 6 is polystyrene and makes up meat trays, egg cartons, clamshell containers, and compact

disc cases.

Type 7 includes all other plastics such a bullet-proof materials, 3- and 5-gallon water bottles,

cell phone and tablet frames, safety goggles and sunglasses.

Advanced Joining Techniques


The use of new techniques and advanced materials is of major interest to automobile and

aerospace manufacturing industries for reduce weight, cost and improve part performance.

For this purpose, techniques for joining lightweight dissimilar materials, particularly aluminum,

steel and plastics are becoming increasingly important in the manufacturing of hybrid structures

and components for engineering applications.

The choice of proper joining technology is an essential aspect of designing and manufacturing

parts.

Joining of dissimilar materials has been given much attention in recent years due to their

superior functional capabilities.



One of the most important combinations of dissimilar materials is aluminum with steel due to its

potential application in aerospace and automotive manufacturing industries.

Despite the many specific benefits, aluminum-steel combination, have a lot of problems like

formation of brittle intermetallic compounds, poor wetting behavior of aluminum, difference in

physical and chemical properties of the base metals, etc.

The melting temperatures of aluminum and steel are quite different.

So, conventional fusion welding process does not yield mechanically good joints.

There is therefore a need to identify new joining methods for new applications for dissimilar

materials.



Self-Pierce Riveting (SPR)

Clinching Methods

Friction Stir Welding (FSW)

Friction Stir Spot Welding (FSSW) Methods

Laser Welding

Zero Waste Manufacturing


Zero Waste is a philosophy that encourages the redesign of resource life cycles so that all

products are reused.

The goal is for no trash to be sent to landfills, incinerators, or the ocean.

In Zero waste the conservation of all resources by means of responsible production,

consumption, reuse, and recovery of all products, packaging, and materials, without burning

them, and without discharges to land, water, or air that threaten the environment or human

health.

Zero waste promotes not only reuse and recycling, but, more importantly, it promotes

prevention and product designs that consider the entire product life cycle.



Zero waste designs strive for reduced materials use, use of recycled materials and use of more

benign materials, longer product lives, reparability, and ease of disassembly at end of life.

Zero waste strongly supports sustainability by protecting the environment, reducing costs and

producing additional jobs in the management and handling of wastes back into the industrial

cycle.

A Zero waste strategy may be applied to businesses, communities, industrial sectors, schools

and homes.



Benefits of Zero wastage include:

Saving money

Faster Progress in production processes

Improving environmental prevention strategies

Supports sustainability: A zero waste strategy

supports all three of the generally accepted

goals of

Sustainability economic well-being and

environmental protection, and social well-being.

Improved new materials like no waste materials

to landfills.

Thank You


SINGURU RAJESHM.Tech (MD), PGDEEM, B.Tech (ME)

Assistant ProfessorRaghu Engineering College(Autonomous)

Dakamarri , Bhimunipatnam Mandal, Visakhapatnam Dist., Andhra Pradesh

Documents

Green Engineering Systems · 2019. 3. 14. · Green Engineering Systems. UNIT-2: ENERGY EFFICIENT PROCESS SYLLABUS ... increase in the number of studies on environmentally conscious