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Sustainable Manufacturing: Resource Efficiency and Innovation Strategies

Explore the concept of sustainability, critical resource demands, energy efficiency in processing, and successful funded programs in the field of sustainable manufacturing. Learn about the triple bottom line approach, focusing on environmental, economic, and social aspects. Discover ways to reduce energy consumption and water footprint, promote circular economy, and improve recycling capabilities in the production of materials like aluminum. Gain insights into global CO2 emissions, key materials, and processing challenges, while also exploring future strategies for a more sustainable manufacturing industry.

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Sustainable Manufacturing: Resource Efficiency and Innovation Strategies

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  1. Sustainability12th December 2013Mark JollyProfessor of SustainableManufacturing

  2. Content • What is Sustainability? • Resource demands & criticality • Energy of processing? • Examples of funded programmes

  3. Content • What is Sustainability? • Resource demands & criticality • Energy of processing? • Examples of funded programmes

  4. Triple bottom line

  5. Triple bottom line:Detail • Environmental • Less raw material; less energy; less carbon; reduced waste; less need for recycling • Economic • Material cost; however less raw material required; reduce transportation expense; shorten the production cycle • Social • Local manufacture; customised design; identification of suitable markets

  6. For aluminium • Reduced energy of primary production (non-UK) • Move to Circular Economy • Dematerialisation (design of product & process) • Design for reuse • Recycle • Reduce energy • Reduce water footprint

  7. Content • What is Sustainability? • Resource demands & criticality • Energy of processing? • Examples of funded programmes

  8. Abundance of metals in the earths crust

  9. Where is Al used? • After “Sustainable Materials – with both eyes open”, Allwood & Cullen

  10. EU critical raw materials (2010) & supply concentration 76% 97% 80% 95% 88% 84% 85% Proportion of global production from: China,South Africa,USA,Brazilin 2010 Source: BGS World Mineral Statistics Database 95%

  11. Content • What is Sustainability? • Resource demands & criticality • Energy of processing for Aluminium? • Examples of funded programmes

  12. Global CO2 emissions & 5 key materials • “Resources, Conservation and Recycling”, Allwood & Ashby

  13. Which resources create most CO2 • After “Resources, Conservation and Recycling”, Allwood & Ashby

  14. Embedded energy

  15. Heat content of liquid metals to 100 ºC superheat

  16. Processing and Manufacturing Issues • Getting useful material from ore is energy intensive (4% world energy for comminution! But non UK) • High energy in manufacturing (36% of global energy usage) • Liquid metal processing (high energy & inefficient) • Cost pressure (low energy cost producers) • Yields (aerospace sometimes <5%)

  17. UK/EU Future • Circular Economy • Improve Reuse and Recycling • Develop better recycling capability (e.g. coping with trace elements) • Develop design for re-use concepts • New business models –tracking? • Light alloys recycling friendly, composites are not

  18. Content • What is Sustainability? • Resource demands & criticality • Energy of processing for Aluminium? • Examples of funded programmes

  19. Research projectsclassification • P: sustainable materials processing (reduced resources) • U: design for sustainable use (e.g. light-weighting) • R: recycling (e.g. development processes/alloys to cope) • E: Extraction (lower use of resources in primary alloy) • T: Material tracking (re-use)

  20. Government funded projects:direct

  21. Government funded projects:indirect

  22. Mixed waste • Axion polymers • Recycles 20% of the auto polymer in UK

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