Browsing by Author "Jolly, Mark"

Now showing 1 - 17 of 17
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    A bespoke carbon footprint framework to set the path towards Net Zero in foundries
    (Elsevier, 2024) Cox, Rylan; Pagone, Emanuele; Jolly, Mark; Salonitis, Konstantinos; Birch, Tim
    A bespoke carbon footprint framework for the metal casting industry is presented to enable swifter carbon accounting of foundries and identify energy and carbon footprint hotspots to support the drive towards Net Zero goals. Many manufacturing enterprises in the United Kingdom and Europe are already struggling to maintain financial competitiveness as well as drive towards a sustainable shift, particularly SMEs. This framework is to help alleviate the pressure on the industry by providing an outside tool to direct companies to sustainable solutions. This paper validates such framework breaking down the environmental footprint of ferrous products through energy and material profiles of sand casting processes in two real UK foundries identified as “A” and “B”. During environmental visits, it was established that Foundry A emitted an average of 41700 tons of CO2 annually and Foundry B 1400 tons. The framework developed to estimate the melting process energy (to be, then, converted into carbon footprint) predicted with about 15% accuracy the actual data. Furthermore, the framework can be expanded and improved on for its accuracy and into other processes within the casting process including melting, core and mould making, pouring sand reclamation, ancillaries and fettling.
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    A conceptual assessment framework for sustainability in the foundation industries
    (Elsevier, 2024) Litos, Lampros; Paddea, Sanjooram; Salonitis, Konstantinos; Jolly, Mark
    Foundation industries in the UK are in constant pursuit of better technological solutions to enhance materials conversion efficiency and supply chain economies of scale. However, sustainable materials and strategies to conserve resources and better utilize waste streams tend to be ever more challenging to achieve when technological advances fall short in being widely adoptable by companies. Knowledge and technology transfer across multiple companies within the same sector (for example, construction materials production) or across seemingly common core processes (such as size reduction or furnaces) must be achieved for sustainability efforts to achieve economies of scale. Part of the reason why this is a difficult endeavor is the lack of visibility of the steps and drivers involved in a circular economy context with a view to achieve scale. Materials and technologies that could help foundation industries become more sustainable are being examined through the introduction of a novel framework that could help companies and policy makers understand where the opportunities exist. In this paper, the authors describe the design and development of the framework and offer examples drawn from an ongoing research and innovation project in foundation industries.
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    Benchmarking of energy consumption and CO2 emissions in cement production: a case study
    (Springer, 2024-02-02) Sarfraz, Shoaib; Sherif, Ziyad; Jolly, Mark; Salonitis, Konstantinos
    In 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.
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    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, Robert
    Dataset 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.
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    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, Konstantinos
    Vacuum-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.
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    Energy benchmarking of manufacturing processes in foundation industries
    (Elsevier, 2024-01-12) Sarfraz, Shoaib; Sherif, Ziyad; Jolly, Mark; Salonitis, Konstantinos
    Benchmarking 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.
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    Environmental impact assessment of titanium swarf cleaning methods
    (KES International, 2024-09-20) Karadimas, Georgios; Pagone, Emanuele; Salonitis, Konstantinos; Jolly, Mark; Williams, Stewart
    This paper evaluates the environmental impacts of chemical based and CryoClean swarf cleaning techniques through a comprehensive Life Cycle Assessment (LCA) aimed at identifying sustainable practices for recycling titanium swarf in additive manufacturing processes. Employing ISO 14040 and 14044 standards, the study focuses on a functional unit of cleaning 100 gr of titanium swarf, enabling direct comparison of environmental footprints across these methods. Data for the inventory analysis includes specific inputs such as energy consumption, water use, and chemicals, alongside outputs like emissions and waste generation, with supplemental secondary data sourced from Ecoinvent. The impact assessment utilizes the ReCiPe methodology, concentrating on key environmental indicators such as Global Warming Potential (GWP) and Acidification Potential (AP). The findings reveal distinct environmental trade-offs between the chemical based and CryoClean methods. Chemical-based cleaning, while effective at removing contaminants, often involves the use of hazardous substances that can lead to significant ecological impacts. In contrast, CryoClean, which utilizes liquid nitrogen to freeze and remove impurities, shows a lower environmental impact across several categories but may require higher energy inputs. By estimating the specific environmental impacts of the selected swarf cleaning techniques, the study contributes valuable insights towards optimizing material recovery and advancing circular economy principles in industrial manufacturing. The paper aims to guide industry stakeholders toward adopting more environmentally sustainable practices that align with the transition to greener manufacturing processes.
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    Greening foundation industries: shared processes and sustainable pathways
    (MDPI, 2023-10-01) Sherif, Ziyad; Sarfraz, Shoaib; Jolly, Mark; Salonitis, Konstantinos
    Foundation industries, encompassing metals, ceramics, cement, paper, chemicals, and glass, play a vital role in driving industrial economies. Despite their pivotal role, a comprehensive understanding of shared processes and their impact on resource utilisation remains elusive. This study employs a novel approach, leveraging an adapted Dependency Structure Matrix (DSM), to unveil the core processes commonly utilised among these industries. These processes are then evaluated based on their influence on energy consumption and CO2 emission. The investigation revealed 18 common processes categorised by their processing principles, their expected outcomes, and the equipment used. Remarkably, these processes emerge as significant contributors to both energy consumption and CO2 emissions. Notably, pyroprocessing emerged as a prevalent practice in five out of the six sectors, while the production of dried products and crushers and mills were the most frequently encountered outcomes and equipment used, respectively. This paper discusses the implications of these findings for foundation industries, emphasising potential areas for enhancing manufacturing operations to reduce environmental damage and facilitate knowledge transfer among the various sectors. Furthermore, the study identifies shared abatement options that can be collectively implemented across industries to achieve more substantial reductions in environmental footprint. By identifying and prioritising the most impactful processes in foundation industries, this study provides a strategic footing for advancing sustainable and efficient manufacturing practices within these critical sectors.
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    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, Konstantinos
    Sustainable 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.
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    Make sustainable manufacturing the heart of the UK's net zero transformation
    (Westminster Publishing Ltd., 2023-07-10) Jolly, Mark
    The 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.
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    Medium entropy alloys for biomedical applications
    (Cranfield University, 2024-06-07) Zhang, Jiacheng; Stiehler, Martin; Syed, Adnan; Jorge Jr, Alberto Moreira; Jolly, Mark; Georgarakis, Konstantinos
    High entropy alloys (HEAs) is a rapidly emerging class of metallic materials consisting of four or more elements in equimolar or quasi-equimolar compositions. These alloys often have simple crystal structures and tailorable properties attracting significant interest for different applications. Common metallic materials for orthopaedic and dental implants include stainless steel, Co-Cr and Ti- alloys. Although these materials are widely in use, issues relevant to biocompatibility and suspected toxicity and the elastic modulus mismatch compared to that of hard tissue have been raised in recent years. High entropy alloys specifically designed for bio-medical applications can offer solutions to overcome these limitations. Bio-HEAs have emerged in the last couple of years and currently receive increasing scientific attention. In this work, we discuss on the design of new entropic alloys using only non-toxic elements such as Ti, Zr, Nb, Ta and Mo. We use a systematic approach to investigate the effect of additional elements on the microstructure and properties of the alloys starting from the binary Ti-Nb and extending to the ternary Ti-Zr-Nb, the quaternary Ti-Zr-Nb-Ta and the Ti-Zr-Nb-Ta-Mo alloy. The alloy design is building on previous work on beta Ti- alloys which has shown promising trends for reducing the elastic modulus of implant materials. The alloys were produced by arc-melting and suction casting under Ar inert atmosphere. X-ray diffraction, and scanning electron microscopy were employed to reveal their crystal structure and microstructure. respectively. The developed alloys exhibit BCC crystal structure and a dendritic microstructure in their as-cast condition. The addition of Zr and Mo was found to increase the hardness of the alloys.
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    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, Stephen
    The 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 material
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    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, Mark
    This 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.
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    Sustainable manufacturing for the future - a white paper
    (Cranfield University, 2016-06-06 16:15) Jolly, Mark
    First 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.
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    Sustainable manufacturing for the future – second white paper
    (Cranfield University, 2016-06-06 16:15) Jolly, Mark
    This 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 Briatin
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    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, Konstantinos
    The 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.
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    The use of Gentani approach for benchmarking resource efficiency in manufacturing industries
    (Springer, 2023-04-26) Sarfraz, Shoaib; Jolly, Mark; Salonitis, Konstantinos
    The majority of today’s manufacturing processes are based on well-developed and well-established procedures that are characteristics of mature technologies. The manufacturing industries have not evolved significantly over time because of recent economic, environmental, and societal advances at an unprecedented rate. As a result, there are numerous challenges and opportunities available, especially regarding resource efficiency. The majority of industrial processes consume far more energy than the theoretical minimal process energy requirements. This paper aims to develop a theoretical framework utilising the Gentani approach whilst targeting the minimum resources needed to carry out a process for use by manufacturing industries. The resource efficiency (exergy) metric has also been discussed that can be used as a tool to evaluate the efficiency of industry, depicting a more holistic level of energy and material consumption. The framework will help manufacturing industries in lowering costs and remain competitive by improving resource efficiency, aimed at reducing resource use and providing value delivery. The study will also assist in transforming these industries into resource-efficient modern manufactories in line with the Net-Zero 2050 agenda.