Browsing by Author "Jolly, Mark"
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Item Open Access Benchmarking of energy consumption and CO2 emissions in cement production: a case study(Springer, 2024-02-02) Sarfraz, Shoaib; Sherif, Ziyad; Jolly, Mark; Salonitis, KonstantinosIn the pursuit of economic growth and value creation, foundation industries including cement, metals, glass, chemicals, paper, and ceramics face formidable challenges related to energy usage, emissions, and resource consumption in their manufacturing operations, all while striving to achieve ambitious Net Zero carbon and green targets. To overcome these challenges and propel sustainable progress, benchmarking emerges as a powerful ally. This study performs a benchmarking analysis of energy use and CO2 emissions for a UK cement plant as well as best available techniques (BAT) investigation to identify opportunities for performance improvement in crucial areas such as energy usage and environmental sustainability. The research utilises industrial data from a 2850 tonne per day capacity dry process cement plant. Key energy and emissions parameters, including thermal and electrical energy intensity, recovered energy and CO2 intensity, are computed per tonne of cement produced along with capacity utilisation across major process stages including raw material grinding, clinkerisation, and cement grinding. Comprehensive data sourced directly from the manufacturer is compared against literature benchmarks for global averages and best practices. Although surpassing global average values, the plant lags European best practices across all metrics, signalling room for substantial improvement. Assessment of relevant BATs for the cement industry reveals prospects to integrate vertical roller mills for cement grinding and use Organic Rankine Cycle (ORC) at the clinkerisation stage. Adopting these techniques could reduce the electrical energy intensity of clinkerisation by 51% and cement grinding electrical intensity by 30%, surpassing benchmarks. While limited to a single cement plant, the study provides a standardised methodology that could be replicated across foundation industries to enable performance tracking and highlight efficiency gaps. The benchmarking approach developed can guide the implementation of energy conservation measures and the adoption of best practices by the cement industry to reduce its carbon footprint.Item Open Access Cellulose filaments derived from dissolution and spinning of paper sludge nanofibers using an ionic liquid Item(Cranfield University, 2020-04-17 09:08) Adu, Cynthia; Zhu, Chenchen; Jolly, Mark; Oksman, Kristiina; Eichhorn, Stephen J.; Richardson, RobertDataset posted on 2020-04-17, 10:08 authored by Cynthia Adu, Chenchen Zhu, Mark Jolly, Kristiina Oksman, Stephen J. Eichhorn, Robert M. Richardson, Kevin D. Potter This data set contains results from the experimental test conducted to dissolve and spin cellulose nanofibres into filaments. The CNF was derived from paper mill sludge by mechanical grinding and dissolved in ionic liquid at 9 and 12% CNF concentration. Fibre pinning was conducted by dry-jet wet spinning method to produce filaments with average tensile strength of 19 GPa and 26 GPa, and modulus of 223 MPa and 282 MPa respectively. Enclose is the data from the tensile tests, rheology of the spinning solution and the filament orientation obtained from the wide angle x-ray of the filament.Item Open Access Defect minimisation in vacuum assisted plaster mould investment casting through simulation of high value aluminium alloy components(Springer, 2023-02-09) Pagone, Emanuele; Jones, Christopher A.; Forde, John; Shaw, William; Jolly, Mark; Salonitis, KonstantinosVacuum-assisted plaster mould investment casting is one of the best available processes to manufacture ultra-high complexity castings for the aerospace and defence sectors. In light of the emerging cross-sectoral manufacturing industry digitalisation, process simulation appears as a very important tool to improve casting yield, reduce metallurgical scrap, and reduce lead time to new product introduction. Considering the unique aspects and the level of customisation of the process system, this work will present a Computational Fluid Dynamics-based simulation tool with bespoke settings (that include thermophysical properties). Optimal fill and solidification parameters are identified for a representative geometry able to describe a variety of very complex, high-value aluminium alloy components through an iterative process.Item Open Access Energy benchmarking of manufacturing processes in foundation industries(Elsevier, 2024-01-12) Sarfraz, Shoaib; Sherif, Ziyad; Jolly, Mark; Salonitis, KonstantinosBenchmarking energy consumption and utilisation has become a crucial tool for the manufacturing sector in the drive towards sustainability. However, incorporating industrial perspectives into benchmarking efforts is necessary to identify effective and relevant metrics. This study aims to evaluate the metrics for benchmarking energy utilisation within the foundation industries by deploying two surveys while incorporating the views of industry and subject matter experts. The study also involved conducting interviews with metal foundries to investigate the energy consumption of their processes and their metrics utilisation. The findings indicate the need for an accurate and reliable method to extract values for energy benchmarking of manufacturing processes. Proper procedures must be in place to ensure the data is collected consistently and uniformly across different processes and organisations. The deployment of effective and relevant metrics through industrial prospection will help ensure the benchmarking process is meaningful, actionable and supports the goal of a more sustainable future.Item Open Access Identification of the right environmental KPIs for manufacturing operations: towards a continuous sustainability framework(MDPI, 2022-11-01) Sherif, Ziyad; Sarfraz, Shoaib; Jolly, Mark; Salonitis, KonstantinosSustainable manufacturing has grown into a major subject of discussion between individuals and organisations around the world. This is attributed to the recognition of the urgency in advancing sustainable manufacturing due to the diminishing non-renewable resources, stricter regulations related to environmental impacts and the increasing consumer preference for environmental-friendly products. However, manufacturing companies have been confronted with a decision on which KPIs to select for appraising their processes, and how they should interpret these KPIs in transforming their processes towards a sustainable future. This paper presents a structured framework for the manufacturing industries to identify the right environmental KPIs. It includes building a database for environmental KPIs, categorising, ranking, and composing a final KPI set for specified targets. The developed method allows for the selection of the most effective KPI in representing a specified target as well as identifying unmonitored environmental aspects. The framework has been corroborated by subject matter and industry experts in which the potential benefits have been verified.Item Open Access Make sustainable manufacturing the heart of the UK's net zero transformation(Westminster Publishing Ltd., 2023-07-10) Jolly, MarkThe UK’s net zero future will depend on making things in sustainable ways, with close attention to the whole cycle: the materials we use, the energy and carbon emissions involved in processes, and the opportunities for re-use, re-manufacturing and (last of all) recycling.Item Open Access Properties of cellulose nanofibre networks prepared from nevEr-dried and dried paper mill sludge(Cranfield University, 2018-08-15 11:11) Adu, Cynthia; Jolly, Mark; Oksman, Kristiina; Zhu, Chenchen; Berglund, Linn; J. Eichhorn, StephenThe data enclosed is the data used in the paper "Properties of cellulose nanofibre networks prepared from never-dried and dried paper mill sludge". The raw data from tensile tests of cellulose nanofibres prepared from paper mill sludge is attached including the x-ray diffraction pattern of the materialItem Open Access Structural packaging foams prepared by uni-directional freezing of paper sludge cellulose nanofibres and poly (vinyl alcohol).(Cranfield University, 2019-04-18 08:36) Adu, Cynthia; Rahatekar, Sameer; Filby, Jyoti; Ayre, David; Jolly, MarkThis dataset contains results from the experimental tests on cellulose nanofibres and polyvinyl alcohol foams prepared by uni-directional freezing. The compression tests of 8 samples are recorded here with their stress-strain curves plotted. Additional parameters of the foams such as density, volume, porosity are also recorded.Item Open Access Sustainable manufacturing for the future - a white paper(Cranfield University, 2016-06-06 16:15) Jolly, MarkFirst white paper on the future of Manufacturing in the Food and Drinks industry in Great Britain based on the outcomes of an Industry-Academia Workshop.Item Open Access Sustainable manufacturing for the future – second white paper(Cranfield University, 2016-06-06 16:15) Jolly, MarkThis second white paper presents the results of 3 x 3 Month studies on the Pathways for Sustainable Manufacturing tin the future in the Food and Drinks Industry in Great BriatinItem Open Access Towards framework development for benchmarking energy efficiency in foundation industries: a case study of granulation process(Springer, 2023-02-14) Sarfraz, Shoaib; Sherif, Ziyad; Jolly, Mark; Salonitis, KonstantinosThe manufacturing sector depends mainly on the foundation industries which have a major contribution to the country’s economy. These foundation industries include glass, metals, ceramics, cement, paper, and chemical sectors that support the demands of our modern lives. On the other hand, these industries are energy intensive. Energy requirements in foundation industries can be improved by benchmarking and comparing the actual energy consumption of individual processes with their theoretical minimum value. In this study, an energy taxonomy approach has been used to identify the elements responsible for energy consumption in the granulation process. Bond’s law has been used to calculate the theoretical minimum energy consumption of one such individual process, i.e., granulation—a common process among the foundation industries which accounts for an average of 50% of the total energy consumption. A framework has also been developed that can be used by foundation industries to benchmark their energy efficiency and that provides an insight into the practical and theoretical potential for reducing their energy requirements.