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ENGT5220 Low Impact Manufacturing

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Question:

An industrial system can be analysed at different levels of detail by considering the energy inputs to the system, the efficiency of its energy conversions and the energy outputs, for example waste heat. Energy is carried around the system in different forms such as hot water, compressed air, gas, electricity and steam. Industrial energy flows can be complex, for example, an energy conversion device such as a boiler (chemical energy to heat energy) might supply industrial process as well as energy used in the building. Similarly, waste heat from a process might be re-used, converted into electricity or exported into a district heating system. Finally, greenhouse gas emissions depend upon the nature of the energy inputs to the industrial system as well as the amount used.

Consider the example of a small (150 employees) manufacturer in the food and drink sector. You may choose the type of product (such as ready meals, beer or another product with which you may be familiar). The owner wishes to audit the energy performance of the organisation because she is considering investments to improve its energy efficiency.

Additional benefits of the audit are that it will identify opportunities for cost and emissions reduction. The factory was built in the 1970s and has not been significantly modified since then. The processes that use heat and the building heating system are fed by steam and hot water from oil fired boilers that are as old as the factory but all other machinery including chillers, compressors, pumps, conveyors, etc. are electrically powered.

  1. Identify the most significant energy using processes within the factory and explain briefly how you would estimate or measure the energy they use.
  2. Illustrate the main flows of energy into, within and out of the factory, showing the main energy conversions that take place with typical efficiencies. Where are the main losses?
  3. Comment on the suitability of renewable energy technologies for this factory and suggest two other ways in which you might reduce the cost of the organisation’s energy use.
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