Browsing by Author "Sherif, Ziyad"
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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 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 Printed carbon nanotube and graphene heaters for drying ceramics(Springer, 2023-02-11) Sherif, Ziyad; Patsavellas, John; Salonitis, KonstantinosThe ceramic manufacturing process has been subject to many advances with the evolution of new technologies. However, there are still some delays and losses in the fundamental process which may be mitigated by deploying alternative technical tools and methods. One such stage is the sensitive pre-drying phase in which ceramic bodies can sustain drying defects such as micro-cracking and fractures due to lack of fine process control. This project investigates the feasibility of using Longwave infrared (LWIR) radiation emitted by a printed Carbon Nanotubes and Graphene (CNTG) heater for pre-drying a clay sample. The CNTG heater emits infrared radiation with a relatively low DC voltage power supply. By radiant heat transfer, homogeneous and uniform drying has been observed in the sample. The penetrative capability of the infrared energy which warms the inside of the sample is presented, as along with the results of comparing the CNTG heater with a silicone mat heater that also emits infrared radiation. The study establishes that the CNTG heater is not only capable of reducing the lead time of ceramics drying using penetrative IR, but also as an efficient and versatile option that can be economically deployed in the pre-drying stage of a ceramic manufacturing process.Item 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.