CERES :: Browsing by Author "Sarfraz, Shoaib"

Browsing by Author "Sarfraz, Shoaib"

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Open Access
A critical review of the decarbonisation potential in the U.K. cement industry
(MDPI, 2025-01-10) Sherif, Ziyad; Sarfraz, Shoaib; Jolly, Mark R.; Salonitis, Konstantinos
As urbanisation and infrastructure development continue to drive rising cement demand, the imperative to significantly reduce emissions from this emissions-intensive sector has become increasingly urgent, especially in the context of global climate goals such as achieving net zero emissions by 2050. This review examines the status, challenges and prospects of low-carbon cement technologies and mitigation strategies through the lens of the U.K. cement industry. A mixed-methods approach was employed, combining structured literature searches across academic databases with analyses of industry reports, market data and technological roadmaps to ensure a comprehensive evaluation. Following an outline of cement production, resource flows and the sector’s landscape in the U.K., the review delves into an array of decarbonisation pathways. This includes deploying the best available technologies (BATs), fuel switching, carbon capture utilisation and storage (CCUS), clinker substitution and low-carbon cement formulations. A critical assessment is provided on the technological readiness, costs, resource availability considerations and scalability aspects governing the widespread implementation prospects of these approaches within the U.K. cement industry. Furthermore, this study proposes a roadmap that considers priority avenues and policy needs essential for facilitating the transition towards sustainable cement production aligned with the U.K.’s net zero obligations by 2050. This evaluation contributes significantly to the ongoing decarbonisation discourse by holistically mapping technological solutions and strategic imperatives tailored to the unique challenges and opportunities presented by the U.K. cement sector.
Open Access
An innovative cost modelling system development for laser drilling process
(Cranfield University, 2019-05-09 10:34) Sarfraz, Shoaib
Poster presented at Cranfield University’s 2019 Manufacturing Doctoral Community event.
Open Access
Benchmark pre-production practice in manufacturing engineering
(IOS Press, 2017-12-31) Shehab, Essam; Rao, Yogeesh; Al-Ashaab, Ahmed; Beadle, Chris; Sarfraz, Shoaib
Prototyping stage is a very important phase of new product development, where many decisions need to be taken to get high quality, zero defect products at the right time with minimum cost. Therefore, any value added improvements or best practices in the prototyping stage will support competitiveness of manufacturing companies. This research aims to benchmark the best practices in prototype part manufacture to support early stages of product introduction. A set of of best practices in the prototype component manufacture, along with validated four step prototyping strategy model and best practice prototype journey path model were developed. Research findings provide insight about prototyping trends, best practices and optimum ways of doing prototyping in the manufacturing companies around the globe. Manufacturing companies can use the developed models and best practices to make better prototype strategy in their new product introduction system to achieve their business objectives.
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 R.; 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.
Open Access
Challenges in cost modelling of recycling carbon fiber composites
(IOS, 2020-07-10) Shehab, Essam; Meiirbekov, Arshyn; Sarfraz, Shoaib
The use of carbon fiber composites (CFCs) has become broad in many industries due to its superior properties compared to conventional materials. However, the increased demand coupled with environmental regulations has led to the development of different recycling methods for CFCs such as mechanical, thermal and chemical processes. Each recycling method has its own requirements and outputs along with some economic implications which need to be justified through cost modelling. This paper aims to identify current challenges associated with cost modelling of different processes for CFC recycling. The main challenges identified are grouped into three main categories such as technical issues, supply chain and market challenges
Open Access
Chapter 5: Comprehensive study on tool wear during machining of fiber-reinforced polymeric composites
(Springer, 2020-12-23) Ismail, Sikiru Oluwarotimi; Sarfraz, Shoaib; Niamat, Misbah; Mia, Mozammel; Gupta, Munish Kumar; Pimenov, Danil Yu; Shehab, Essam
The use of fiber reinforced polymeric (FRP) composites has increased rapidly, especially in many manufacturing (aerospace, automobile and construction) industries. The machining of composite materials is an important manufacturing process. It has attracted several studies over the last decades. Tool wear is a key factor that contributes to the cost of the machining process annually. It occurs due to sudden geometrical damage, frictional force and temperature rise at the tool-work interaction region. Moreover, tool wear is an inevitable, gradual and complex phenomenon. It often causes machined-induced damage on the workpiece/FRP composite materials. Considering the geometry of drill, tool wear may occur at the flank face, rake face and/or cutting edge. There are several factors affecting the tool wear. These include, but are not limited to, drilling parameters and environments/conditions, drill/tool materials and geometries, FRP composite compositions and machining techniques. Hence this chapter focuses on drilling parameters, tool materials and geometries, drilling environments, types of tool wear, mechanisms of tool wear and methods of measurement of wear, effects of wear on machining of composite materials and preventive measures against rapid drill wear. Conclusively, some future perspectives or outlooks concerning the use of drill tools and their associated wears are elucidated, especially with the advancement in science and technology
Open Access
A critical review of 3D printing and digital manufacturing in construction engineering
(Emerald, 2022-02-15) Ali, Md. Hazrat; Issayev, Gani; Shehab, Essam; Sarfraz, Shoaib
Purpose In recent years, 3D printing technologies have been widely used in the construction industry. 3D printing in construction is very attractive because of its capability of process automation and the possibility of saving labor, waste materials, construction time and hazardous procedures for humans. Significant researches were conducted to identify the performance of the materials, while some researches focused on the development of novel techniques and methods, such as building information modeling. This paper aims to provide a detailed overview of the state-of-the-art of currently used 3D printing technologies in the construction areas and global acceptance in its applications. Design/methodology/approach The working principle of additive manufacturing in construction engineering (CE) is presented in terms of structural design, materials used and theoretical background of the leading technologies that are used to construct buildings and structures as well as their distinctive features. Findings The trends of 3D printing processes in CE are very promising, as well as the development of novel materials, will gain further momentum. The findings also indicate that the digital twin (DT) in construction technology would bring the industry a step forward toward achieving the goal of Industry 5.0. Originality/value This review highlights the prospects of digital manufacturing and the DT in construction engineering. It also indicates the future research direction of 3D printing in various constriction sectors.
Open Access
Effect of different dielectrics on material removal rate, electrode wear rate and microstructures in EDM
(Elsevier, 2017-05-09) Niamat, Misbah; Sarfraz, Shoaib; Aziz, Haris; Jahanzaib, Mirza; Shehab, Essam; Ahmad, Wasim; Hussain, Salman
Diesinker electric discharge machining is widely used non-conventional technique for making high precision and complex shaped parts. Dielectrics and electrical parameters were considered as the main factors for EDM performance. In this paper, the effects of pulse-on-time (μs) and current (ampere) were evaluated for performance measures using kerosene and water as dielectrics. A comparison was performed for both dielectrics in terms of material removal rate (mm3/min), electrode wear rate (mm3/min), and microstructures. Aluminum 6061 T6 alloy was used as material for this research due to its extensive use in aerospace and automotive industries. Experiments were designed using Taguchi L9 orthogonal array (OA). Time series graphs were plotted to compare material removal rate and electrode wear rate. Microstructures were taken by scanning electron microscope to analyze the surface produced in terms of cracks, globules and micro-holes. Higher material removal rate and lower electrode wear were achieved with kerosene dielectric. The novelty of this research work, apart from its practical application, is that Aluminum 6061 T6 alloy is used as work material to compare the performance of dielectrics (kerosene and distilled water). Paper presented at: Complex Systems Engineering and Development Proceedings of the 27th CIRP Design Conference Cranfield University, UK 10th – 12th May 2017.
Open Access
Enabling net-zero GHG emissions in the UK metals and transport industries through a circular supply chain framework
(Elsevier, 2024-05) Adeyemi, Olabisi I.; Sarfraz, Shoaib; Salonitis, Konstantinos
The UK metals industry is indispensable in achieving the country’s net-zero greenhouse gas (GHG) emissions target by 2050, especially considering the heavy reliance of the transport sector on metals. This paper proposes strategies based on recycling and refining locally sourced scrap metals to build a robust circular supply chain. Findings revealed that 16% of global crude steel is used in transport and this accounts for 8% of the world’s GHG emissions. Domestically, iron and steel account for 14% of the UK industrial emissions, with over 8 million metric tons of scrap metals exported annually. Insights from stakeholders revealed export dependency and infrastructure gaps impeding circularity. Collaborative efforts between industry, government, and recyclers are vital. Investing in electric arc furnaces and storage can enable the processing of domestic metal scrap for high-quality yield. A closed-loop flow of battery-critical metals will also support sustainable manufacturing of electric vehicles. Ultimately, this paper advocates systemic efforts across policy, technology, infrastructure, and partnerships to realise a sustainable supply chain in the metals industry aligned with the decarbonisation and circular economy goals.
Open Access
Energy benchmarking of manufacturing processes in foundation industries
(Elsevier, 2024-01-12) Sarfraz, Shoaib; Sherif, Ziyad; Jolly, Mark R.; 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.
Open Access
Environmental assessment of recycling carbon fibre-reinforced composites: current challenges and future opportunities
(Springer, 2022-11-19) Meiirbekov, Arshyn; Amantayeva, Akniyet; Tokbolat, Serik; Suleimen, Aidar; Sarfraz, Shoaib; Shehab, Essam
The increasing application of carbon fiber reinforced polymer composites (CFRP) across different industries raises environmental concerns. It requires focusing on the end-of-life phase of the product/material. The environmental benefits of CFRP recycling over conventional ways of treatment are apparent. However, estimating the environmental impacts is followed up with various challenges. In this study, the aspects of environmental assessment of CFRP recycling and their respective challenges are examined. CFRP recycling methods such as mechanical treatment, pyrolysis, fluidized bed process, and solvolysis have been previously studied in the context of energy and environmental assessment under the Life-Cycle-Assessment (LCA) framework. This study focused on the identification of challenges associated with variability of applied methods used, comparability, scaling results, data, uncertainty, and resource-demanding process of LCA. Recommendations on overcoming the identified challenges are provided and discussed.
Open Access
Evaluation of productivity and operating cost of laser drilling process – a case study
(IOS Press, 2018-09-13) Sarfraz, Shoaib; Shehab, Essam; Salonitis, Konstantinos
Laser drilling is a non-conventional machining process which is widely used in automotive, electronics and aerospace sectors to produce holes in diverse range of materials. Different types of lasers and methods are available to produce various hole geometries. Big number of researchers have examined several ways to enhance the performance of this process by investigating different process parameters and drilling methods, that seek improvement of the drilled hole quality. Whereas, productivity and operating cost are also important factors which need to be evaluated along with drilled hole quality. Reducing the drilling time can improve productivity and the selection of a suitable laser can save operating cost which will benefit laser processing industries in this global competitive environment. A case study was performed using different lasers for single pulse and percussion drilling. A significant improvement in productivity was observed with the use of a high power laser that is subject to high operating cost.
Open Access
Evaluation of the influence of dissolved nitrates on corrosion behaviour of ship structural steel exposed to seawater environment
(Elsevier, 2024-04-15) Abbas, Muntazir; Rizvi, Syed Haider Mehdi; Sarfraz, Shoaib; Raza, Asif; Khan, Asif; Loya, Adil; Najib, Antash
Corrosion rates in marine structural steels differ significantly with the varying compositions of seawater particularly near harbours or coastal regions primarily due to the presence of untreated chemically active species from various sources. The reviewed literature reports accelerated steel corrosion losses in coastal seawater exposure conditions, which has widely been attributed to the presence of aggressive chemical compounds e.g., dissolved inorganic nitrogenous (DINs) compounds, sulphur containing compounds, in combination with various other environmental factors and their interdependent complex relationships. This paper aims to investigate the influence of nitrates, a DIN compound, on the corrosion behaviour of a low carbon ship structural steel, by exposing surface the cleaned coupons to an artificial seawater solution in a controlled laboratory environment. The uniform and localised corrosion damages were measured on steel coupons by using the standard weight loss and the dimensional metrology methods. A significant increase in corrosion losses was observed on coupons exposed to the nitrate-added artificial seawater than those exposed to similar seawater compositions with no additional nitrate content. Elemental compositions of corrosion deposits and corrosion morphologies investigated using various analytical tools such as SEM, EDS and Raman scattering techniques have shown different types of corrosion products in both exposure conditions.
Open Access
Experimental characterization of electrical discharge machining of aluminum 6061 T6 alloy using different dielectrics
(King Fahd University of Petroleum & Minerals, 2019-07-08) Niamat, Misbah; Sarfraz, Shoaib; Shehab, Essam; Ismail, Sikiru Oluwarotimi; Khalid, Qazi Salman
Electrical discharge machining is a non-traditional machining method broadly employed in industries for machining of parts that have typical profiles and require great accuracy. This paper investigates the effects of electrical parameters: pulse-on-time and current on three performance measures (material removal rate, microstructures and electrode wear rate), using distilled water and kerosene as dielectrics. A comparison between dielectrics for the machining of aluminum 6061 T6 alloy material in terms of performance measures was performed. Aluminum 6061 T6 alloy material was selected, because of its growing use in the automotive and aerospace industrial sectors. The experimental sequence was designed using Taguchi technique of L9 orthogonal array by changing three levels of pulse-on-time and current, and test runs were performed separately for each dielectric. The results obtained show that greater electrode wear rate (EWR) and higher material removal rate (MRR) were achieved with distilled water when compared with kerosene. These greater EWR and MRR responses can be attributed to the early breakage of the weak oxide and carbide layers formed on the tool and alloy material surfaces, respectively. The innovative contributions of this study include, but are not limited to, the possibility of machining of aluminum 6061 T6 alloy with graphite electrode to enhance machinability and fast cutting rate employing two different dielectrics.
Open Access
Experimental investigation of productivity, specific energy consumption, and hole quality in single-pulse, percussion, and trepanning drilling of IN 718 superalloy
(MDPI, 2019-12-04) Sarfraz, Shoaib; Shehab, Essam; Salonitis, Konstantinos; Suder, Wojciech
Laser drilling is a high-speed process that is used to produce high aspect ratio holes of various sizes for critical applications, such as cooling holes in aero-engine and gas turbine components. Hole quality is always a major concern during the laser drilling process. Apart from hole quality, cost and productivity are also the key considerations for high-value manufacturing industries. Taking into account the significance of improving material removal quantity, energy efficiency, and product quality, this study is performed in the form of an experimental investigation and multi-objective optimisation for three different laser drilling processes (single-pulse, percussion, and trepanning). A Quasi-CW fibre laser was used to produce holes in a 1 mm thick IN 718 superalloy. The impacts of significant process parameters on the material removal rate (MRR), specific energy consumption (SEC), and hole taper have been discussed based on the results collected through an experimental matrix that was designed using the Taguchi method. The novelty of this work focuses on evaluating and comparing the performance of laser drilling methods in relation to MRR, SEC, and hole quality altogether. Comparative analysis revealed single-pulse drilling as the best option for MRR and SEC as the MRR value reduces with percussion and trepanning by 99.70% and 99.87% respectively; similarly, percussion resulted in 14.20% higher SEC value while trepanning yielded a six-folds increase in SEC as compared to single-pulse drilling. Trepanning, on the other hand, outperformed the rest of the drilling processes with 71.96% better hole quality. Moreover, optimum values of parameters simultaneously minimising SEC and hole taper and maximising MRR are determined using multi-objective optimisation.
Open Access
An experimental investigation on Cryo-LN2 turning of hardened steel: a sustainability assessment
(IOS Press, 2019-09-12) Khan, Aqib Mashood; Jamil, Muhammad; Hao, Xiuqing; Ning, He; Sarfraz, Shoaib; Goher, Kamran; Shehab, Essam
To achieve an excellent workpiece surface quality and long tool life in machining of hardened steel is an inordinate challenge. Recently, conventional flood cooling assisted machining processes are used to address this problem. However, such proposed processes have adverse effects on the environment as well as on the machine shop worker’s health. Hence, in this study, the effects of traditionally used flood cooling and sustainable Cryo-LN2 techniques on the six machining indices, such as surface roughness, cutting power, energy consumption, tool life, tool wear, and productivity in the external turning of AISI-52100 have been investigated. Comparative results showed that Cryo-LN2 technique outperformed flood cooling for all measured indices. The Cryo-LN2 assisted turning process yielded 18% less energy consumption and 66% more productivity. The findings of the current study encourage metal processing industries to use such type of sustainable techniques in the machine shop.
Open Access
Greening foundation industries: shared processes and sustainable pathways
(MDPI, 2023-10-01) Sherif, Ziyad; Sarfraz, Shoaib; Jolly, Mark R.; 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.
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 R.; 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.
Open Access
An integrated analysis of productivity, hole quality and cost estimation of single-pulse laser drilling process
(Sage, 2020-11-03) Sarfraz, Shoaib; Shehab, Essam; Salonitis, Konstantinos; Suder, Wojciech; Niamat, Misbah; Jamil, Muhammad
Laser drilling is a well-established manufacturing process utilised to produce holes in various aeroengine components. This research presents an experimental investigation on the effects of laser drilling process parameters on productivity (material removal rate), hole quality (hole taper) and drilling cost. Single-pulse drilling was employed to drill a thin-walled Inconel 718 superalloy plate of 1mm thickness using pulsed Nd:YAG laser. The experiments were designed using Box-Behnken statistical approach to investigate the impacts of pulse energy, pulse duration, gas pressure and gas flow rate on the selected responses. Multi-objective optimisation was performed using response surface methodology (RSM) based grey rational analysis (GRA) to identify optimal drilling conditions aiming to maximise the MRR and minimise hole taper and drilling cost. The optimal combination of drilling parameters was found as pulse energy of 20 J, pulse duration of 6 ms, gas pressure of 100 psi and gas flow rate of 40 mm3/s. A detailed cost analysis identified labour cost, gas consumption and machine costs as the major cost elements of the laser drilling process
Open Access
Internal cracks and non-metallic inclusions as root causes of casting failure in sugar mill roller shafts
(MDPI, 2019-08-03) Jamil, Muhammad; Khan, Aqib Mashood; Hegab, Hussien; Sarfraz, Shoaib; Sharma, Neeraj; Mia, Mozammel; Gupta, Munish Kumar; Zhao, GuLong; Moustabchir, H.; Pruncu, Catalin I.
The sugar mill roller shaft is one of the critical parts of the sugar industry. It requires careful manufacturing and testing in order to meet the stringent specification when it is used for applications under continuous fatigue and wear environments. For heavy industry, the manufacturing of such heavy parts (>600 mm diameter) is a challenge, owing to ease of occurrence of surface/subsurface cracks and inclusions that lead to the rejection of the final product. Therefore, the identification and continuous reduction of defects are inevitable tasks. If the defect activity is controlled, this offers the possibility to extend the component (sugar mill roller) life cycle and resistance to failure. The current study aims to explore the benefits of using ultrasonic testing (UT) to avoid the rejection of the shaft in heavy industry. This study performed a rigorous evaluation of defects through destructive and nondestructive quality checks in order to detect the causes and effects of rejection. The results gathered in this study depict macro-surface cracks and sub-surface microcracks. The results also found alumina and oxide type non-metallic inclusions, which led to surface/subsurface cracks and ultimately the rejection of the mill roller shaft. A root cause analysis (RCA) approach highlighted the refractory lining, the hot-top of the furnace and the ladle as significant causes of inclusions. The low-quality flux and refractory lining material of the furnace and the hot-top, which were possible causes of rejection, were replaced by standard materials with better quality, applied by their standardized procedure, to prevent this problem in future production. The feedback statistics, evaluated over more than one year, indicated that the rejection rate was reduced for defective production by up to 7.6%.