Wim Dewulf

Methodology for systematic analysis and improvement of manufacturing unit process life cycle inventory (UPLCI) CO2PE! initiative (cooperative effort on process emissions in manufacturing). Part 2: case studies

PurposeThis report proposes a life-cycle analysis (LCA)-oriented methodology for systematic inventory analysis of the use phase of manufacturing unit processes providing unit process datasets to be used in life-cycle inventory (LCI) databases and libraries. The methodology has been developed in the framework of the CO2PE! collaborative research programme (CO2PE! 2011a) and comprises two approaches with different levels of detail, respectively referred to as the screening approach and the in-depth approach.MethodsThe screening approach relies on representative, publicly available data and engineering calculations for energy use, material loss, and identification of variables for improvement, while the in-depth approach is subdivided into four modules, including a time study, a power consumption study, a consumables study and an emissions study, in which all relevant process in- and outputs are measured and analysed in detail. The screening approach provides the first insight in the unit process and results in a set of approximate LCI data, which also serve to guide the more detailed and complete in-depth approach leading to more accurate LCI data as well as the identification of potential for energy and resource efficiency improvements of the manufacturing unit process. To ensure optimal reproducibility and applicability, documentation guidelines for data and metadata are included in both approaches. Guidance on definition of functional unit and reference flow as well as on determination of system boundaries specifies the generic goal and scope definition requirements according to ISO 14040 (2006) and ISO 14044 (2006).ResultsThe proposed methodology aims at ensuring solid foundations for the provision of high-quality LCI data for the use phase of manufacturing unit processes. Envisaged usage encompasses the provision of high-quality data for LCA studies of products using these unit process datasets for the manufacturing processes, as well as the in-depth analysis of individual manufacturing unit processes.ConclusionsIn addition, the accruing availability of data for a range of similar machines (same process, different suppliers and machine capacities) will allow the establishment of parametric emission and resource use estimation models for a more streamlined LCA of products including reliable manufacturing process data. Both approaches have already provided useful results in some initial case studies (Kellens et al. 2009; Duflou et al. (Int J Sustain Manufacturing 2:80–98, 2010); Santos et al. (J Clean Prod 19:356–364, 2011); UPLCI 2011; Kellens et al. 2011a) and the use will be illustrated by two case studies in Part 2 of this paper (Kellens et al. 2011b).

Environmental Analysis of the Air Bending Process

This paper presents the results of a data collection effort, allowing to assess the overall environmental impact of the air bending process using the CO2PE!‐Methodology. First the different modes of the air bending process are investigated, including both productive and non‐productive modes. In particular consumption of electric power is recorded for the different modes. Subsequently, time studies allow determining the importance of productive and nonproductive modes of the involved process. The study demonstrates that the influence of standby losses can be substantial. In addition to life cycle analysis, in depth process analysis also provides insight in achievable environmental impact reducing measures towards machine tool builders and eco‐design recommendations for product developers. The energy consumption of three different machine tool architectures are analysed and compared within this paper.

Solid state recycling of aluminium alloys via a porthole die hot extrusion process: Scaling up to production

Whereas industrial symbiosis has led to increased energy and resource efficiency in process industries, this concept has not yet been applied in discrete product manufacturing. Metal scrap is first conventionally recycled, for which substantial energy and resource efficiency losses have been reported. Recent research has however proven the feasibility of ‘meltless’ recycling of light metal scrap, yielding a first glimpse of potential industrial symbiosis. Various solid state recycling techniques (such as recycling via hot extrusion or Spark Plasma Sintering) have been proposed for scrap consolidation directly into bulk products or semis by physical disruption and dispersion of the oxide surface film by imposing significant plastic and shear strain. Solid State Recycling (SSR) methods can omit substantial material losses as they bypass the metallurgical recycling step. In this context the case of direct production of bulk aluminium profiles via hot extrusion at industrial scale is demonstrated within this paper. The extrusion tests were performed directly into the production line, highlighting the scaling up potentials and the industrial relevance of this research. A significant amount of machining chips were collected, chemically cleaned and cold compacted into chip based billets with ∼80% relative density. Afterwards the scrap consolidation was achieved by imposing significant plastic and shear deformation into the material during hot extrusion through a modified 2-porthole extrusion die-set. The production process sequence along with microstructural investigations and mechanical properties comparison of the cast based profile used as reference versus the chip based profile are presented.Whereas industrial symbiosis has led to increased energy and resource efficiency in process industries, this concept has not yet been applied in discrete product manufacturing. Metal scrap is first conventionally recycled, for which substantial energy and resource efficiency losses have been reported. Recent research has however proven the feasibility of ‘meltless’ recycling of light metal scrap, yielding a first glimpse of potential industrial symbiosis. Various solid state recycling techniques (such as recycling via hot extrusion or Spark Plasma Sintering) have been proposed for scrap consolidation directly into bulk products or semis by physical disruption and dispersion of the oxide surface film by imposing significant plastic and shear strain. Solid State Recycling (SSR) methods can omit substantial material losses as they bypass the metallurgical recycling step. In this context the case of direct production of bulk aluminium profiles via hot extrusion at industrial scale is demonstrated within this ...

Stimulating Students to Experience Sustainable Engineering: The CQS Group T Racing Team

Stimulating engineering students to experience how to leverage technology for a sustainable world should form a key element of today’s engineering education. Therefore, GROUP T - International University College Leuven offers its Master students the opportunity to participate in a so called “Entrepreneurial Engineering Experience”. An example is the CQS Group T Racing Team, where students developed both an electric and bio-fuelled race vehicle based on the chassis of a Citroen 2CV. The achievements of this team will be highlighted in this paper to illustrate how the program stimulates the self-development of engineering skills and entrepreneurship within a sustainability mindset.