Category Archives: Energy Efficiency

Use Circular Manufacturing to Save Energy and Reduce Waste

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The industrial sector is the third biggest source of greenhouse gas emissions in the world, accounting for over 20% of total emissions (including carbon dioxide and methane), the Intergovernmental Panel on Climate Change reveals. Manufacturing plants (as part of the industrial sector) typically involve significant pollution and energy and resource use. By implementing sustainable methods designed to green the manufacturing process, manufacturing plants can improve their environmental footprint, lower costs, and boost efficiency.

environmental benefits of circular manufacturing

Embrace circular manufacturing

Circular manufacturing (also known as lean manufacturing) is a sustainable model that extends the life and use of materials and goods to minimize waste and energy and resource usage. In particular, circular manufacturing may include: converting to a renewable power source; adopting predictive maintenance to extend the condition and longevity of equipment; and sharing equipment with other plants.

Additionally, curricular manufacturing typically involves recovering and reusing resources or waste materials generated from other plants rather than purchasing new raw materials. Just look at Kalundborg Symbiosis as a solid example of circular manufacturing: they’re a collective of nine Danish manufacturing companies who’ve been sharing material, water, and energy streams since 1961. Together they lower their carbon emissions by 635,000 tons and save 24 million EUR every year.

Partner with eco-friendly businesses

Your manufacturing plant likely partners with other businesses whether it’s to source raw parts, equipment, and materials or purchase packaging. By partnering with green businesses, you can in turn ensure your business stays as eco-friendly as possible. For example, switch to an energy supplier committed to green energy or a packaging supplier that uses recycled materials.

packaging waste

Packaging that adorns your product can have serious environmental impact.

Additionally, more and more manufacturers are entering the online selling space and partnering with ecommerce companies. In 2020, for example, 30% of manufacturing and 30% of distribution companies generated 60%-80% of their total profits from B2B ecommerce. By using a quick and efficient method of ecommerce fulfillment, manufacturing businesses can ensure they’re harnessing automation and technology to maximum advantage.

Update machinery and equipment

Old machinery and equipment typically have higher energy demands than necessary. By replacing or updating your old machinery and equipment, you can reduce energy waste and increase efficiency and productivity. Installing an electric power management system (EPMS) will also let you clearly see your plant’s electricity distribution and capacity and better control your energy and power costs. Moreover, if it’s within your budget, you can also consider investing in automation in your plant to improve energy-efficiency and reduce waste.

robotics in sustainable manufacturing

For example, “cobots” (aka collaborative robots) are designed to work alongside human employees. By taking care of dangerous or repetitive tasks, cobots can improve safety for workers (the manufacturing industry typically racks up 400,000 non-fatal injuries every year) while increasing productivity and minimizing risk of human error.

Bottom Line

Implementing sustainable changes to your manufacturing plant will pay off greatly in the long run. By embracing circular manufacturing, partnering with eco-friendly businesses, and upgrading machinery and equipment, you can lower your carbon footprint, cut costs, and improve efficiency.

Biomass Gasification Power Systems

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Biomass gasification power systems have followed two divergent pathways, which are a function of the scale of operations. At sizes much less than 1MW, the preferred technology combination today is a moving bed gasifier and ICE combination, while at scales much larger than 10 MW, the combination is of a fluidized bed gasifier and a gas turbine.

biomass-gasifier

Larger scale units than 25 MW would justify the use of a combined cycle, as is the practice with natural gas-fired gas turbine stations. In the future it is anticipated that extremely efficient gasification based power systems would be based on a combined cycle that incorporates a fuel cell, gas turbine  and possibly a Rankine bottoming cycle.

Integrated Gasification Combined Cycle

The most attractive means of utilising a biomass gasifier for power generation is to integrate the gasification process into a gas turbine combined cycle power plant. This will normally require a gasifier capable of producing a gas with heat content close to 19 MJ/Nm3. A close integration of the two parts of the plant can lead to significant efficiency gains.

The syngas from the gasifier must first be cleaned to remove impurities such as alkali metals that might damage the gas turbine. The clean gas is fed into the combustor of the gas turbine where it is burned, generating a flow of hot gas which drives the turbine, generating electricity.

Hot exhaust gases from the turbine are then utilised to generate steam in a heat recovery steam generator. The steam drives a steam turbine, producing more power. Low grade waste heat from the steam generator exhaust can be used within the plant, to dry the biomass fuel before it is fed into the gasifier or to preheat the fuel before entry into the gasifier reactor vessel.

Schematic of integrated biomass gasification combined cycle

The gas-fired combined cycle power plant has become one of the most popular configurations for power generation in regions of the world where natural gas is available. The integration of a combined cycle power plant with a coal gasifier is now considered a potentially attractive means of burning coal cleanly in the future.

Biomass Fuel Cell Power Plant

Another potential use for the combustible gas from a biomass gasification plant is as fuel for a fuel cell power plant. Modern high temperature fuel cells are capable of operating with hydrogen, methane and carbon monoxide. Thus product gas from a biomass gasifier could become a suitable fuel.

As with the integrated biomass gasification combined cycle plant, a fuel cell plant would offer high efficiency. A future high temperature fuel cell burning biomass might be able to achieve greater than 50% efficiency.