Energy Management in Plastics Processin: Strategies, Targets, Techniques, and Tools

Description

Energy Management in Plastics Processing: Strategies, Targets, Techniques, and Tools, Third Edition, addresses energy benchmarking and site surveys, how to understand energy supplies and bills, and how to measure and manage energy usage and carbon footprinting. The book's approach highlights the need to reduce the kWh/kg of materials processed and the resulting permanent reductions in consumption and costs. Every topic is covered in a 2-page spread, providing the reader with clear actions and key tips for success. This revised third edition covers new developments in energy management, power supply considerations, automation, assembly operations, water footprinting, and transport considerations, and more. Users will find a practical workbook that not only shows how to reduce energy consumption in all the major plastics shaping processes (moulding, extrusion, forming), but also provides tactics that will benefit other locations in plants (e.g. in factory services and nonmanufacturing areas). Front Cover Energy Management in Plastics Processing: Strategies, targets, techniques and tools Copyright Contents Preface to the 3rd Edition Chapter 1. Introduction to energy management 1.1 Where we are going 1.2 The drivers for energy management 1.3 The importance of energy costs 1.4 The efforts, opportunities and obstacles 1.5 Energy management systems – the basics 1.6 Energy management systems – the standard 1.7 Energy management systems – the changing standard 1.8 Energy management – where are you now? 1.9 Financial management – where are you now? 1.10 Technical management – where are you now? 1.11 Awareness and information – where are you now? 1.12 Purchasing – where are you now? 1.13 Project assessment and selection 1.14 Energy management projects – where are you now? Key tips Chapter 2. Energy benchmarking 2.1 The framework and energy use drivers 2.2 The basic internal site data 2.3 The effect of management 2.4 The effect of the process 2.5 Variations on the site base and process loads 2.6 What do we want to do? 2.7 Assessing site performance – internal benchmarking 2.8 Assessing site performance – past performance 2.9 Budgeting for future site energy use 2.10 Complex sites – multi-variate analysis 2.11 Site SEC and production volume 2.12 External site benchmarking – general 2.13 External site benchmarking – injection moulding 2.14 External site benchmarking – extrusion 2.15 External site benchmarking – extrusion blow moulding 2.16 External site benchmarking – rotational moulding 2.17 External machine benchmarking – general 2.18 External machine benchmarking – injection moulding 2.19 External machine benchmarking – injection blow moulding 2.20 External machine benchmarking – extrusion 2.21 External machine benchmarking – extrusion blow moulding 2.22 External machine benchmarking – thermoforming Key tips Chapter 3. Targeting and controlling energy costs 3.1 Understanding energy use – the basics 3.2 Understanding energy use – the site energy map 3.3 Integrating energy into the accounts – monitoring and targeting 3.4 Data collection and analysis 3.5 Setting targets 3.6 Reporting energy costs 3.7 The energy dashboard report 3.8 Capital expenditure and equipment selection 3.9 Verifying energy savings – the theory 3.10 Verifying energy savings – the practice 3.11 The energy manager’s job 3.12 Targeting and controlling – where are you now? Key tips Chapter 4. Services 4.1 Power supply – electricity terms 4.2 Power supply – reducing electricity costs 4.3 Power supply – transformers 4.4 Power supply – voltage management 4.5 Power supply – electricity supplier data 4.6 Power supply – analysing interval data 4.7 Power supply – sub-metering 4.8 Power supply – gas 4.9 Power supply – solar and wind 4.10 Power supply – combined heat and power and tri-generation (CCHP) 4.11 Power supply – what to do when it fails (power outages) 4.12 Power supply – where are you now? 4.13 Motors – understanding motor use and costs 4.14 Motors – the programme 4.15 Motors – minimise the demand: turn it off 4.16 Motors – minimise the demand: reduce transmission losses 4.17 Motors – minimise the demand: reduce the load at source 4.18 Motors – optimise the supply: get the right size motor 4.19 Motors – optimise the supply: improve the motor efficiency 4.20 Motors – optimise the supply: slow the motor down 4.21 Motors – optimise the supply: the savings from slowing motors down 4.22 Motors – motor maintenance and management 4.23 Motors – where are you now? 4.24 Compressed air – the system 4.25 Compressed air – the programme 4.26 Compressed air – minimise the demand: reduce leakage 4.27 Compressed air – minimise the demand: reduce use 4.28 Compressed air – optimise the supply: improve generation 4.29 Compressed air – optimise the supply: optimise treatment 4.30 Compressed air – optimise the supply: improve distribution 4.31 Compressed air – heat recovery 4.32 Compressed air – where are you now? 4.33 Cooling water – the programme 4.34 Cooling water – minimise the demand: reduce heat gains 4.35 Cooling water – minimise the demand: increase temperatures 4.36 Cooling water – optimise the supply: reduce cooling costs with chillers 4.37 Cooling water – optimise the supply: reduce cooling costs with cooling towers 4.38 Cooling water – optimise the supply: reduce cooling costs with free cooling 4.39 Cooling water – optimise the supply: reduce cooling costs with ground water 4.40 Cooling water – optimise the supply: reduce distribution costs 4.41 Cooling water – where are you now? 4.42 Drying – the programme 4.43 Drying – minimise the demand: dry the right materials 4.44 Drying – minimise the demand: store materials correctly 4.45 Drying – optimise the supply: improve control systems and insulation 4.46 Drying – optimise the supply: reduce drying costs with desiccant drying 4.47 Drying – optimise the supply: reduce drying costs with other methods 4.48 Drying – where are you now? 4.49 Vacuum generation 4.50 Hydraulics systems 4.51 Robots 4.52 Fans Key tips Chapter 5. Processing 5.1 Processing – where are we going? 5.2 Injection moulding – where does all the energy go? 5.3 Injection moulding – the basics 5.4 Injection moulding – machine selection 5.5 Injection moulding – machine monitoring 5.6 Injection moulding – process setting 5.7 Injection moulding – motors 5.8 Injection moulding – new and retrofitted VSDs 5.9 Injection moulding – all electric machines 5.10 Injection moulding – heating 5.11 Injection moulding – mould temperature controllers 5.12 Injection moulding – mould design 5.13 Injection moulding – hydraulic fluid 5.14 Injection moulding – IMM energy rating 5.15 Injection moulding – where are you now? 5.16 Extrusion – general 5.17 Extrusion – motors 5.18 Extrusion – heating 5.19 Extrusion – profiles 5.20 Extrusion – profiles: calibration and cooling 5.21 Extrusion – sheet 5.22 Extrusion – blown film 5.23 Extrusion – oriented film 5.24 Extrusion – other processes 5.25 Extrusion – where are you now? 5.26 Extrusion blow moulding – general 5.27 Extrusion blow moulding – extrusion and blowing 5.28 Extrusion blow moulding – heating and cooling 5.29 Extrusion blow moulding – tops and tails management 5.30 Extrusion blow moulding – where are you now? 5.31 Injection blow moulding 5.32 Injection blow moulding – where are you now? 5.33 Injection stretch blow moulding – general and moulding 5.34 Injection stretch blow moulding – blowing 5.35 Injection stretch blow moulding – where are you now? 5.36 Thermoforming – general and pre-heating 5.37 Thermoforming – heat losses 5.38 Thermoforming – heating and cooling 5.39 Thermoforming – where are you now? 5.40 Rotational moulding – general 5.41 Rotational moulding – reducing process heat losses 5.42 Rotational moulding – other process improvements 5.43 Rotational moulding – where are you now? 5.44 EPS foam moulding – PCL and steam 5.45 EPS foam moulding – process 5.46 EPS foam moulding – where are you now? 5.47 Compression moulding 5.48 Pultrusion 5.49 Rubber – general 5.50 Rubber – storage and mixing 5.51 Rubber – moulding 5.52 Regranulation – general 5.53 Regranulation – processes Key tips Chapter 6. Operations 6.1 Operations – making it work 6.2 Setting, start-up, stand-by and shut-down 6.3 Using interval data in operations 6.4 Tool changeover and quality control 6.5 Training and employee involvement 6.6 The benefits of employee training 6.7 Processing operations – where are you now? 6.8 Maintenance 6.9 Small power equipment 6.10 Small power equipment – where are you now? 6.11 Process control 6.12 Process control – where are you now? Key tips Chapter 7. Buildings and offices 7.1 Buildings and offices 7.2 Lighting – general 7.3 Lighting – controls and maintenance 7.4 Lighting – where are you now? 7.5 Heating – general 7.6 Heating – controls and maintenance 7.7 Heating – where are you now? 7.8 Hot water – where are you now? 7.9 Air conditioning 7.10 Air conditioning – where are you now? 7.11 Building fabric 7.12 Building fabric – where are you now? Key tips Chapter 8. Site surveys 8.1 A mini site survey – the energy walkaround (the treasure hunt) 8.2 Preparing for a site survey – information 8.3 Preparing for a site survey – tools 8.4 Planning the initial site survey 8.5 Carrying out the initial site survey 8.6 Reporting the initial site survey 8.7 Following up the initial site survey Key tips Chapter 9. Carbon footprinting 9.1 The basics of carbon footprinting 9.2 Site carbon footprinting – Scope 1 9.3 Site carbon footprinting – Scope 2 9.4 Site carbon footprinting – Scope 3 9.5 Site carbon footprinting – putting the scopes together 9.6 Product carbon footprinting 9.7 Country plastics processing carbon footprints 9.8 Carbon footprinting – where are you now? Key tips Appendices Appendix 1 Submitting site data Appendix 2 Submitting machine data Postscript Abbreviations and acronyms Back Cover