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E-grāmata: Energy Management in Plastics Processing: Strategies, Targets, Techniques, and Tools

(Tangram Technology Ltd.)
  • Formāts: PDF+DRM
  • Izdošanas datums: 06-Jul-2018
  • Izdevniecība: Elsevier / The Lancet
  • Valoda: eng
  • ISBN-13: 9780081025086
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Energy Management in Plastics Processing: Strategies, Targets, Techniques, and ToolsPalielināt
  • Formāts: PDF+DRM
  • Izdošanas datums: 06-Jul-2018
  • Izdevniecība: Elsevier / The Lancet
  • Valoda: eng
  • ISBN-13: 9780081025086
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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).

  • Enables plastics processors in their desire to institute an effective energy management system, both in processing and elsewhere in the plant
  • Provides a holistic perspective, shining a light on areas where energy management methods may have not been previously considered
  • Acts as a roadmap to help companies move towards improved sustainability and cost savings
Preface 1(2)
1 Introduction to energy management
3(30)
1.1 Where we are going
4(2)
1.2 The drivers for energy management
6(2)
1.3 The importance of energy costs
8(2)
1.4 The efforts, opportunities and obstacles
10(2)
1.5 Energy management systems -- the basics
12(2)
1.6 Energy management systems -- the standard
14(2)
1.7 Energy management systems -- the changing standard
16(2)
1.8 Energy management-where are you now?
18(2)
1.9 Financial management -- where are you now?
20(2)
1.10 Technical management -- where are you now?
22(2)
1.11 Awareness and information -- where are you now?
24(2)
1.12 Purchasing -- where are you now?
26(2)
1.13 Project assessment and selection
28(2)
1.14 Energy management projects -- where are you now?
30(3)
Key tips
32(1)
2 Energy benchmarking
33(46)
2.1 The framework and energy use drivers
34(2)
2.2 The basic internal site data
36(2)
2.3 The effect of management
38(2)
2.4 The effect of the process
40(2)
2.5 Variations on the site base and process loads
42(2)
2.6 What do we want to do?
44(2)
2.7 Assessing site performance -- internal benchmarking
46(2)
2.8 Assessing site performance -- past performance
48(2)
2.9 Budgeting for future site energy use
50(2)
2.10 Complex sites -- multi-variate analysis
52(2)
2.11 Site SEC and production volume
54(2)
2.12 External site benchmarking -- general
56(2)
2.13 External site benchmarking -- injection moulding
58(2)
2.14 External site benchmarking -- extrusion
60(2)
2.15 External site benchmarking -- extrusion blow moulding
62(2)
2.16 External site benchmarking -- rotational moulding
64(2)
2.17 External machine benchmarking -- general
66(2)
2.18 External machine benchmarking -- injection moulding
68(2)
2.19 External machine benchmarking -- injection blow moulding
70(2)
2.20 External machine benchmarking -- extrusion
72(2)
2.21 External machine benchmarking -- extrusion blow moulding
74(2)
2.22 External machine benchmarking -- thermoforming
76(3)
Key tips
78(1)
3 Targeting and controlling energy costs
79(26)
3.1 Understanding energy use -- the basics
80(2)
3.2 Understanding energy use -- the site energy map
82(2)
3.3 Integrating energy into the accounts -- monitoring and targeting
84(2)
3.4 Data collection and analysis
86(2)
3.5 Setting targets
88(2)
3.6 Reporting energy costs
90(2)
3.7 The energy dashboard report
92(2)
3.8 Capital expenditure and equipment selection
94(2)
3.9 Verifying energy savings -- the theory
96(2)
3.10 Verifying energy savings -- the practice
98(2)
3.11 The energy manager's job
100(2)
3.12 Targeting and controlling -- where are you now?
102(3)
Key tips
104(1)
4 Services
105(106)
4.1 Power supply -- electricity terms
106(2)
4.2 Power supply -- reducing electricity costs
108(2)
4.3 Power supply -- transformers
110(2)
4.4 Power supply -- voltage management
112(2)
4.5 Power supply -- electricity supplier data
114(2)
4.6 Power supply -- analysing Interval data
116(2)
4.7 Power supply -- sub-metering
118(2)
4.8 Power supply -- gas
120(2)
4.9 Power supply -- solar and wind
122(2)
4.10 Power supply -- combined heat and power and tri-generation (CCHP)
124(2)
4.11 Power supply -- what to do when it fails (power outages)
126(2)
4.12 Power supply -- where are you now?
128(2)
4.13 Motors -- understanding motor use and costs
130(2)
4.14 Motors -- the programme
132(2)
4.15 Motors -- minimise the demand: turn it off
134(2)
4.16 Motors -- minimise the demand: reduce transmission losses
136(2)
4.17 Motors -- minimise the demand: reduce the load at source
138(2)
4.18 Motors -- optimise the supply: get the rig ht size motor
140(2)
4.19 Motors -- optimise the supply, improve the motor efficiency
142(2)
4.20 Motors -- optimise the supply: slow the motor down
144(2)
4.21 Motors -- optimise the supply: the savings from slowing motors down
146(2)
4.22 Motors -- motor maintenance and management
148(2)
4.23 Motors -- where are you now?
150(2)
4.24 Compressed air -- the system
152(2)
4.25 Compressed air -- the programme
154(2)
4.26 Compressed air -- minimise the demand: reduce leakage
156(2)
4.27 Compressed air -- minimise the demand: reduce use
158(2)
4.28 Compressed air -- optimise the supply: improve generation
160(2)
4.29 Compressed air -- optimise the supply: optimise treatment
162(2)
4.30 Compressed air -- optimise the supply: improve distribution
164(2)
4.31 Compressed air -- heat recovery
166(2)
4.32 Compressed air -- where are you now?
168(2)
4.33 Cooling water -- the programme
170(2)
4.34 Cooling water -- minimise the demand: reduce heat gains
172(2)
4.35 Cooling water -- minimise the demand: increase temperatures
174(2)
4.36 Cooling water -- optimise the supply: reduce cooling costs with chillers
176(2)
4.37 Cooling water -- optimise the supply: reduce cooling costs with cooling towers
178(2)
4.38 Cooling water -- optimise the supply: reduce cooling costs with free cooling
180(2)
4.39 Cooling water -- optimise the supply: reduce cooling costs with ground water
182(2)
4.40 Cooling water -- optimise the supply: reduce distribution costs
184(2)
4.41 Cooling water -- where are you now?
186(2)
4.42 Drying -- the programme
188(2)
4.43 Drying -- minimise the demand: dry the right materials
190(2)
4.44 Drying -- minimise the demand: store materials correctly
192(2)
4.45 Drying -- optimise the supply: improve control systems and insulation
194(2)
4.46 Drying -- optimise the supply, reduce drying costs with desiccant drying
196(2)
4.47 Drying -- optimise the supply: reduce drying costs with other methods
198(2)
4.48 Drying -- where are you now?
200(2)
4.49 Vacuum generation
202(2)
4.50 Hydraulics systems
204(2)
4.51 Robots
206(2)
4.52 Fans
208(3)
Key tips
210(1)
5 Processing
211(108)
5.1 Processing -- where are we going?
212(2)
5.2 Injection moulding -- where does all the energy go?
214(2)
5.3 Injection moulding -- the basics
216(2)
5.4 Injection moulding -- machine selection
218(2)
5.5 Injection moulding -- machine monitoring
220(2)
5.6 Injection moulding -- process setting
222(2)
5.7 Injection moulding -- motors
224(2)
5.8 Injection moulding -- new and retrofitted VSDs
226(2)
5.9 Injection moulding -- all-electric machines
228(2)
5.10 Injection moulding -- heating
230(2)
5.11 Injection moulding -- mould temperature controllers
232(2)
5.12 Injection moulding -- mould design
234(2)
5.13 Injection moulding -- hydraulic fluid
236(2)
5.14 Injection moulding -- IMM energy rating
238(2)
5.15 Injection moulding -- where are you now?
240(2)
5.16 Extrusion -- general
242(2)
5.17 Extrusion -- motors
244(2)
5.18 Extrusion -- heating
246(2)
5.19 Extrusion -- profiles
248(2)
5.20 Extrusion -- profiles: calibration and cooling
250(2)
5.21 Extrusion -- sheet
252(2)
5.22 Extrusion -- blown film
254(2)
5.23 Extrusion -- oriented film
256(2)
5.24 Extrusion -- other processes
258(2)
5.25 Extrusion -- where are you now?
260(2)
5.26 Extrusion blow moulding -- general
262(2)
5.27 Extrusion blow moulding -- extrusion and blowing
264(2)
5.28 Extrusion blow moulding -- heating and cooling
266(2)
5.29 Extrusion blow moulding -- tops and tails management
268(2)
5.30 Extrusion blow moulding -- where are you now?
270(2)
5.31 Injection blow moulding
272(2)
5.32 Injection blow moulding -- where are you now?
274(2)
5.33 Injection stretch blow moulding -- general and moulding
276(2)
5.34 Injection stretch blow moulding -- blowing
278(2)
5.35 Injection stretch blow moulding -- where are you now?
280(2)
5.36 Thermoforming -- general and pre-heating
282(2)
5.37 Thermoforming -- heat losses
284(2)
5.38 Thermoforming -- heating and cooling
286(2)
5.39 Thermoforming --where are you now?
288(2)
5.40 Rotational moulding -- general
290(2)
5.41 Rotational moulding -- reducing process heat losses
292(2)
5.42 Rotational moulding -- other process improvements
294(2)
5.43 Rotational moulding -- where are you now?
296(2)
5.44 EPS foam moulding -- PCL and steam
298(2)
5.45 EPS foam moulding -- process
300(2)
5.46 EPS foam moulding -- where are you now?
302(2)
5.47 Compression moulding
304(2)
5.48 Pultrusion
306(2)
5.49 Rubber -- general
308(2)
5.50 Rubber -- storage and mixing
310(2)
5.51 Rubber-moulding
312(2)
5.52 Regranulation -- general
314(2)
5.53 Regranulation -- processes
316(3)
Key tips
318(1)
6 Operations
319(26)
6.1 Operations-making it work
320(2)
6.2 Setting, start-up, stand-by and shut-down
322(2)
6.3 Using interval data in operations
324(2)
6.4 Tool changeover and quality control
326(2)
6.5 Training and employee involvement
328(2)
6.6 The benefits of employee training
330(2)
6.7 Processing operations -- where are you now?
332(2)
6.8 Maintenance
334(2)
6.9 Small power equipment
336(2)
6.10 Small power equipment -- where are you now?
338(2)
6.11 Process control
340(2)
6.12 Process control -- where are you now?
342(3)
Key tips
344(1)
7 Buildings and offices
345(26)
7.1 Buildings and offices
346(2)
7.2 Lighting -- general
348(2)
7.3 Lighting -- controls and maintenance
350(2)
7.4 Lighting -- where are you now?
352(2)
7.5 Heating -- general
354(2)
7.6 Heating -- controls and maintenance
356(2)
7.7 Heating -- where are you now?
358(2)
7.8 Hot water -- where are you now?
360(2)
7.9 Air conditioning
362(2)
7.10 Air conditioning -- where are you now?
364(2)
7.11 Building fabric
366(2)
7.12 Building fabric -- where are you now?
368(3)
Key tips
370(1)
8 Site surveys
371(16)
8.1 A mini site survey -- the energy walk-around (the treasure hunt)
372(2)
8.2 Preparing for a site survey -- information
374(2)
8.3 Preparing for a site survey -- tools
376(2)
8.4 Planning the initial site survey
378(2)
8.5 Carrying out the initial site survey
380(2)
8.6 Reporting the initial site survey
382(2)
8.7 Following up the initial site survey
384(3)
Key tips
386(1)
9 Carbon footprinting
387(18)
9.1 The basics of carbon footprinting
388(2)
9.2 Site carbon footprinting -- Scope 1
390(2)
9.3 Site carbon footprinting -- Scope 2
392(2)
9.4 Site carbon footprinting -- Scope 3
394(2)
9.5 Site carbon footprinting -- putting the scopes together
396(2)
9.6 Product carbon footprinting
398(2)
9.7 Country plastics processing carbon footprints
400(2)
9.8 Carbon footprinting -- where are you now?
402(3)
Key tips
404(1)
Appendices
405(5)
Appendix 1 Submitting site data
406(2)
Appendix 2 Submitting machine data
408(2)
Postscript 410(1)
Abbreviations and acronyms 411
Dr Robin Kent has a B.Eng.(Hons.) in Materials Engineering from Monash University (Australia) and a Ph.D. in Polymer Physics from the University of Surrey (UK)). He has been involved with polymer processing since 1971 and has worked as Technical Director for several of the major plastics processing and window systems companies in UK and Europe. He has published over 400 technical and management papers on plastics and windows and 6 books on plastics processing. He regularly lectures on energy management in plastics processing and materials technology throughout the world. He has chaired 5 committees setting standards for the UK plastics and window industry and is a regular judge for major plastics and glazing industry awards.
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