Integrating energy efficiency performance in production management – gap analysis between industrial needs and scientific literature

For governments and for manufacturing companies, global warming, rising energy prices, and customers’ increasing ecological awareness have pushed energy efficient manufacturing to the top of the agenda. Governments and companies are both striving to identify the most effective measures to increase energy efficiency in manufacturing processes. Based on results of a recent EU-funded roadmapping project, this paper highlights the needs of industrial companies for integrating energy efficiency performance in production management. First, it analyses concepts and tools for measurement, control and improvement of energy efficiency in production management proposed in literature. Second, the paper outlines that ICT tools and standardization are important enablers for energy efficient manufacturing. Third, industrial needs in these areas are presented based on expert interviews. The industrial needs thus identified are contrasted with concepts proposed in literature to point out the implementation gaps between practice and theory. The paper demonstrates that there exists a gap between the solutions available and the actual implementation in industrial companies. It concludes by deriving requirements for energy management in production that future collaborative research projects should address.     

Aerobic in situ stabilization of Landfill Konstanz Dorfweiher: Leachate quality after 1 year of operation

Modern landfill understanding points out controlled operation of landfills. Emissions from landfills are caused mainly by anaerobic biodegradation processes which continue for very long time periods after landfill closure. In situ landfill stabilization aims controlled reduction of emissions towards reduced expenditures as well as aftercare measures. Since April 2010, a new in situ stabilization technique is being applied at a pilot scale landfill (BAIV) within Landfill Konstanz Dorfweiher. This new method utilizes intermittent aeration and leachate recirculation for waste stabilization. In this study, influence of this technique on leachate quality is investigated. Among many other parameters, leachate analyses were conducted for COD, BOD₅, NH₄–N, NO₂–N, NO₃–N, TKN and chloride besides continuously on site recorded pH, electrical conductivity and oxidation–reduction potential (ORP). Results from leachate quality analyses showed that biological activity in the landfill was accelerated resulting in initial higher leachate strength and reduced emission potential of landfill. During full scale in situ aeration, ambient conditions differ from optimized laboratory scale conditions which mainly concern temperature increase and deficient aeration of some landfill parts (Ritzkowski and Stegmann, 2005). Thus, as a field application results of this study have major importance on further process optimization and application.     

Sequentielle Schwermetallextraktion aus Staubniederschl?gen und Stra?ensedimenten Teil I: Sequentielle Schwermetallextraktion von Mikroproben

Für die Anwendung der sequentiellen Schwermetallextraktion auf Proben, die nur im Milligramm-Bereich erhalten werden k?nnen (Mikroproben, wie z. B. Staubniederschl?ge), wurde die Methode vonZeien &Brümmer (1989) weiterentwickelt. Der Extraktionsma?stab wurde um den Faktor 1∶100 verringert und die Reproduzierbarkeit des Verfahrens mit variablen Probenmengen um 20mg und einem Extraktionsvolumen von 500 μl mit Hilfe von Standardb?den nachgewiesen. M?gliche Einflüsse variabler Extraktionsverh?ltnisse (Verh?ltnis von Probenmenge zu Extraktionsvolumen) sowie eine aufwendige Vorbehandlung von Staubproben, die nach der Bergerhoff-Methode (VDI 2119/2, 1972) gesammelt wurden, lagen bei diesen Untersuchungen weitgehend im Variationsbereich des Verfahrens. Die sequentielle Extraktion kann folglich zur Untersuchung der Mobilisierbarkeit von Schwermetallen auch aus Mikroproben mit variablen Probenmengen eingesetzt werden. Mit Hilfe dieses Verfahrens wurden die Mobilisierbarkeiten von Zink, Kupfer und Blei der Schluff- und Tonfraktion von Stra?ensedimenten mit Staubniederschl?gen an zwei urbanen Standorten mit unterschiedlicher, verkehrsbedingter Schwermetallbelastung verglichen. Diese Untersuchungen werden in Teil 2 (“Sequentielle Schwermetallextraktion von st?dtischen St?uben”) vorgestellt.     

Regulating the hydrolysis of organic wastes by micro-aeration and effluent recirculation

In this study, the effects of micro-aeration and liquid recirculation on the hydrolysis of vegetable and flower wastes during two-phase solid–liquid anaerobic digestion were assessed. To accomplish this, we evaluated the hydrolysis of five batches of waste that were treated under the following conditions: anaerobic, insufficient micro-aeration (aeration for 5 min every 24 h), and sufficient micro-aeration (aeration for 5 min every 12, 4 and 1 h). Hydrolysis was found to depend on the level of micro-aeration. Specifically, insufficient micro-aeration led to unstable and decreased performance. Conversely, sufficient micro-aeration promoted the hydrolysis of easily biodegradable carbohydrates and proteins, but the microbial activity was later impaired by liquid recirculation using methanogenic effluent. The hydrolysis efficiency under anaerobic conditions was comparable to the efficiency observed under sufficient micro-aeration, while the cumulative TOC of the anaerobic batch was 1.4–2.4 times higher than that of the micro-aerated batches. In addition, liquid recirculation did not have a negative effect on the development of microbial activity under anaerobic conditions, which resulted in the lignocelluloses having a higher hydrolysis efficiency.     

Toxicity of waters from two streams to early life stages of brown trout (Salmo trutta f. fario L.), tested under semi-field conditions.

The development of brown trout (Salmo trutta f. fario L.) in water of two differently polluted streams and in a control situation was monitored in order to get insights into the impact of anthropogenic chemical stressors on the reproductive success of this fish species indigenous to both streams. The test streams, situated in the south of Stuttgart, Germany, were the complexly polluted K?rsch stream and the less polluted Kr?henbach stream. Bypass systems connected to the streams and a laboratory control system were used for continuous exposure of early brown trout stages shortly after fertilisation up to the end of the embryonic development. Temperature and oxygen conditions were standardised in all test series in order to minimise unspecific effects. The examined endpoints were: (1) mortality, (2) developmental rate, (3) time course of hatching, (4) malformations, and (5) growth. A retarded development, reduced growth rates and higher mortality rates of K?rsch stream water exposed embryos indicated an embryotoxic potential for the more polluted stream. High infection-related mortality rates of embryos suggested the presence of confounding factors also in the less polluted Kr?henbach stream. In parallel to the exposure experiment, physicochemical and limnochemical parameters as well as concentrations of organic contaminants and heavy metals were monitored. Analytical data confirm the different degrees of pollution of both streams.     

Modelling local and synoptic scale influences on ozone concentrations in a topographically complex region of Southern Italy

A modelling study with the on-line coupled Eulerian chemical-weather model WRF/Chem for the Southern Italian region around Cosenza (Calabria) was conducted to identify the influences of synoptic scale meteorology, local scale wind systems and local emissions on ozone concentrations in this orographically complex region. Four periods of 5–7 days were chosen, one from each season, which had wind pattern characteristics representative of typical local climatological conditions, in order to study the local versus non-local impacts on ozone transport and formation. To account for the complex terrain, the horizontal resolution of the smallest modelling domain was 3 km. Model results were compared with measurements to demonstrate the capability of the model to reproduce ozone concentrations in the region. The comparison was favourable with a mean bias of ?1.1 ppb. The importance of local emissions on ozone formation and destruction was identified with the use of three different emission scenarios. Generally the influence of regional emissions on the average ozone concentration was small. However during periods when mountain-sea wind systems were well developed and synoptic scale winds were weak, the influence of local emissions from the urban area was at its greatest. The maximum influence of local emissions on ozone concentrations was 18 ppb.     

A Bayesian network analysis of workplace accidents caused by falls from a height

This article analyses, using Bayesian networks, the circumstances surrounding workplace tasks performed using auxiliary equipment (ladders, scaffolding, etc.) that may result in falls. The information source was a survey of employees working at a height. We were able to determine the usefulness of this approach – innovative in the accident research field – in identifying the causes that have the greatest bearing on accidents involving auxiliary equipment: in these cases, the adoption of incorrect postures during work and a worker’s inadequate knowledge of safety regulations. Likewise, the duration of tasks was also associated with both these variables, and therefore, with the accident rate. Bayesian networks also enable dependency relationships to be established between the different causes of accidents. This information – which is not usually furnished by conventional statistical methods applied in the field of labour risk prevention – allow a causality model to be defined for workplace accidents in a more realistic way. With this statistic tool, the expert is also provided with useful information that can be input to a management model for labour risk prevention.