Energy-Efficient Manufacturing
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Energy-Efficient Manufacturing Eberhard Abele* Institut f€ ur Produktionsmanagement, Technologie und Werkzeugmaschinen, Technische Universit€at Darmstadt, Darmstadt, Germany
Synonyms Energy consumption; Energy demand; Energy efficiency; Sustainable manufacturing
Definition Efficiency in general is a measure of the economy of a process and quantifies the ratio of benefit to effort. In order to evaluate the utilization of the input energy of a system or process, the measure of energy efficiency has been established. In this context, the input energy corresponds to the effort, the objective to be achieved to the benefit (M€ uller et al. 2009): Energy efficiency ¼
Benefit Energy input
(1)
For example, in terms of a metal-cutting machine tool, the benefit corresponds to the physical cutting energy necessary to achieve the desired workpiece transformation. Thus, the energy efficiency of a manufacturing system can reach a theoretical maximum value of one. Due to the ever-present energy conversion losses and the need to process auxiliary functions, such as machine or process cooling, this figure cannot be achieved within real manufacturing systems (Dahmus and Gutowski 2004).
Theory and Application Energy Efficiency Potentials Within Industrial Production Besides the private sector and transportation, the industrial sector is one of the biggest consumers of electric energy within the European Union (Motor Challenge Program 2006). The major part of the electric power consumption is attributable to electrical drives which are mainly used for providing secondary functions within production systems like cooling, pumping, and compressed air (compare Fig. 1). Throughout the worldwide manufacturing industry, considerable potentials for improving energy efficiency do exist. Widespread industrial technologies include: compressed air and pump systems, air-conditioning, cooling, and conveying technology. The electric energy consumption and the associated costs for these cross-cutting technologies can be decreased in most companies by 5–50 % (Fig. 2) (Motor Challenge Program 2006). The payback periods are usually less than 2 years; the returns on capital are usually at about 25 %. Thus, energy efficiency measures in industry can be economically very attractive (BMWi 2010).
*Email: [email protected] Page 1 of 6
CIRP Encyclopedia of Production Engineering DOI 10.1007/978-3-642-35950-7_16792-1 # CIRP 2014
Allocation of electricity consumption within the producing industry in Germany
Allocation of electricity consumption of electric drives driven systems
Electric Drives
Lightning, IT
Compressed air
Cold production
HVAC
Process heat
Pumping
Ventilation
Other
5%
Other
0%
10% 32%
25%
14%
6% 64%
14%
30%
Fig. 1 Overall allocation of electricity consumption in Germany/EU (Motor Challenge Program 2006)
Average energy saving potential
45% 40% 35% 30% 25% 20%
Compressed air Cold production Pumping Ventilation
15% 10% 5% 0% Compressed air Cold production
Pumping
Ventilation
Fig. 2 Electric energy-saving potentials (
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