A method for energy optimization and product quality improvement in manufacturing processes

Denis Clodic, Ecole des Mines de Paris, Centre Energétique et Procédés, France
Bachir Abou Khalil, Marc Berthou, and Thomas Perrotin, EDF R&D Les Renardières Département Eco-efficacité et Procédés Industriels , France

Keywords

manufacturing processes, energy efficiency, product quality, minimum energy requirement, small and medium-sized-enterprises, energy saving, best available technologies, method

Abstract

Manufacturing processes are diverse by nature. Consequently, energy efficiency of each process requires a specific analysis leading to significant costs, SMEs (Small and Medium-sized-Enterprises) cannot always sustain such costs.

The present paper introduces a method for Energy Optimisation of manufacturing processes and product quality improvement during manufacturing. This innovative method is based on a 4-step analysis that allows to rapidly identifying the potential energy savings in industrial processes.

The 4-step method consists in: (1) the process definition, (2) the analysis of the detailed synopsis of production lines (considering energy and mass fluxes), (3) the analysis of energy consumptions and production volumes, and (4) energy efficiency assessment by identification of energy savings and technical option proposals.

The first step is based on the preliminary expertise of the considered process. Process efficiency is analysed based on the theoretical minimum energy requirement, leading to the identification of the best available technologies (BATs) for the considered process, and the optimal energy efficiency.

For the second and third steps, specific data of the process are collected. The process energy consumption and the production information are obtained from the production manager. When needed, measurements could be performed to complete the energy and mass balances. The actual energy efficiency of the manufacturing process is then calculated.

The fourth step consists in the comparison of the different energy ratios. Based on these ratios and on the knowledge of the actual process, energy savings are evaluated, technical solutions for energy efficiency improvement are proposed and first economic analysis is carried out.