Techno-economic impact assessments of energy efficiency improvements in the industrial combustion systems

Industrial energy efficiency assessments not only provide benefits to manufacturers, but also generate significant economic and environmental benefits to localities, states, and the nation through indirect and induced benefits. Quantifying these benefits requires a systematic economic framework for capturing these interactions. This article employs methodologies for improving the energy efficiency of small and medium-size industry through their combustion systems. Combustion systems offer large opportunities to enhance energy efficiency through adopting advanced technologies and better-informed operations. The case studies presented illuminate the potential savings and impacts from implementing energy-efficient combustion recommendations and the importance of energy audits and energy efficiency in the fight against climate change. This study describes and quantifies the cascading economic and environmental impacts of implementing the industrial energy efficiency recommendations offered by an energy auditing program by participating facilities over a ten-year period. Results showed that it is expected that a total of $185M would be saved in energy costs and 2.3 million metric tons of carbon dioxide emissions would be avoided annually, and about 972 jobs could be created in the studied region if all the combustion recommendations would be implemented. The broader view afforded by the proposed study can be used to support better energy efficient practices in manufacturing facilities, communities, and states.

Production of Ti–1.5Al–1Mn Titanium Alloy Butt Joints by Friction Stir Welding

A focus towards industrial energy efficiency explains the current interest in light and high-strength materials and welding and processing technologies. Among the latest popular materials are titanium alloys, which are difficult to process and weld. The problem of joining can be solved by friction stir welding. In the present paper, the mechanical properties and structure of a friction stir welded Ti–1.5Al–1Mn titanium alloy were studied. Alloy behavior in friction stir welding is poorly known; therefore, special attention was paid to the welding process—process modes, torque, and axial force. For the first time, Ti–1.5Al–1Mn joints with 92% of their base metal strength were produced by friction stir welding. Additionally, the important role of the axial load in welding was demonstrated. Axial load increases adhesion and mass transfer. A tool made of ZhS32 nickel heat-resistant superalloy received low wear after 1.5 m of welding. A layer with coarse grains was first found in the subsurface of the stir zone—this layer results from repeated recrystallization behind the tool due to the thermal effect of the shoulders and the low thermal conductivity of the material.

A user workflow for combining process simulation and pinch analysis considering ecological factors

This paper aims to develop an innovative and practical method to accelerate Pinch Analysis problems using a combination of process integration, process simulation tools, and life cycle assessment techniques to design effective industrial energy efficiency measures rapidly. Data extraction and analysis is accelerated using the workflow, reducing pinch analysis duration, and therefore cost. This lowers financial barriers and is expected to help facilitate an increase in the number of conducted pinch analyses each year. An innovative ecological targeting step has been included in the workflow, which represents the option for end-users to further their CO2 savings, once energy targeting has been completed on a purely cost basis. It is expected that optimizing for costs first will enable the implementation of heat recovery solutions in industry. The methodology is applied to an example case study, and the learnings from industrial application is reported.