UNIVERSIDAD DE LA COSTA

ARTICULO 4
Bolstering
Manufacturing Advances

PROFESOR:
ING. LUIS PATERNINA TAPIAS
PROCESOS INDUSTRIALES

PRESENTADO POR:
JAIME ANDRES PEUELA GOMEZ

23 DE FEBRERO DEL 2015

Bolstering
Manufacturing Advances
New tools, heat-recovery systems, and smart control systems are just some the
industrial and manufacturing advancements percolating in research
laboratories across the nation. But they top the list of projects culled by the
U.S. Department of Energy (DOE) through its Clean Energy Manufacturing
Initiative, designed to increase U.S. competitiveness in production of clean
energy products and manufacturing competitiveness through better energy
productivity. Five groups of research teams from universities and private
industry recently divided $25.5 million in DOE grants to pursue their projects
that could benefit automotive and other manufacturing processes and the
burgeoning shale oil industry through lower production costs of essential
materials and reduced energy needs. The project with the most potential to
affect industry-wide operations is from a team led by the University of Texas at
Austin that will develop a tool to integrate performance metrics, models and
simulations with real-time plant energy data. It should help manufacturers
optimize energy productivity in real-time and, in turn, reduce waste and
improve energy efficiency by up to 30 percent, claims the team.

SMART Manufacturing
UT is part of a group that includes the Smart Manufacturing Leadership
Coalition, a nonprofit organization comprised of industry, government and
university members. It plans to develop the nations first open smart
manufacturing technology platform for collaborative industrial network
applications.
Together, we intend to transform industrial productivity and energize a new
era of innovation by empowering manufacturers with real-time, plant-wide
workflow intelligence needed to deliver higher levels of game-changing
competitiveness, states Dean Bartles, SMLC chairman and senior vice
president of General Dynamics, Falls Church, VA. Smart manufacturing
infrastructures and approaches will also let operators make real-time use of
big data flows from fully instrumented plants to improve safety,
environmental impact and energy, water and materials use. The overall
objectives of the initial project are to design and demonstrate a common
platform that enables data modeling and simulation technologies to actively
manage energy use in conjunction with plant production systems. It will show
how real-time management of energy use as a key driver in business decisions
can be applied across a wide range of manufacturing companies of varying
sizes. According to Tom Edgar, UT professor of chemical engineering and
director of its Energy Institute, By combining high-fidelity modeling and novel
sensors, we can perform real-time control and optimization of process

equipment to achieve significant reductions in energy consumption. "Ideally,

progressive business leaders will soon view their plants and factories as
innovation hubs and profit centers to be invested in rather than just cost
centers to be cut with such little strategic value that they sometimes have
been outsourced overseas, says Denise Swink, CEO of SMLC, Inc. We expect
the Smart Manufacturing Platform will unleash American ingenuity and
engineering prowess in ways that are as unexpected as how the IT revolution
has changed every other aspect of our lives.

Stamping and Forming

Other projects chosen by DOE include Ford Motor Co.s effort to develop a new
tool to simultaneously create features on both sides of sheet metal. The
company claims it would eliminate the need for customized tooling like
castings and dies, and would reduce scrap and energy production by 70%,
possibly lowering production costs by 90%. At the Colorado School of Mines,
Golden, CO, Metallurgical and Materials Engineering Professor Emmanuel De
Moor is working with a group of industry partners to develop a roomtemperature stamping technique to replace hot stamping for the manufacture
of advanced high-strength, lightweight steel. It could dramatically reduce costs
and energy needed to manufacture aircraft, vehicles, and other large
equipment. Presently, hot stamping at temperatures of up to 900 degrees
Centigrade is needed to produce high-strength steel. The Mines project will
alter the materials microstructures to exhibit high strength and formability at
room temperature. Besides reducing energy costs for manufacturing, the final
product will reduce vehicle weight along with fuel consumption, say project
leaders.
The holy grail is to not only increase strength but improve ductility at lower
temperatures says De Moor. The process was first proposed in 2003 by John
Speer, professor of metallurgical and materials engineering at the School of
Mines. This project will move the process to the industrial floor. The goal is to
get it to the front door of the industry, says De Moor. Theres a lot of exciting
things happening in the steel industry.

Energy Recovery
In Ithaca, NY, Novamer will lead a project to convert waste carbon dioxide from
industrial sources and ethane derivatives garnered from shale gas to chemical
intermediates that are used in applications such as paints, coatings, textiles
and plastic polymers. It is expected to reduce cradle-to-grave energy usage by
20 to 40 percent. TIAX LLC, Lexington, MA, is developing a new technology to
convert waste heat from manufacturing and industrial processes to electric
power, partnering with Green Mountain Coffee to help reduce energy needed
by coffee roasters. According to DOE, medium-grade waste heat can be
converted to electric power using a novel, scalable scroll expander having an

isentropic expansion efficiency of 75 to 80 percent for a broad range of organic

Rankine cycle boiler pressures, condensing temperatures, and speeds.
Estimates suggest the system would generate net income in three years and
provide national energy savings of 0.90 TBtu/year just for natural gas from
coffee roasting applications alone. These projects come one year after DOE
awarded the 13 advanced manufacturing grants, which now join the Clean
Energy Manufacturing Initiative. The program is founded on partnerships with
thought
leaders,
manufacturers,
innovators,
government
agencies,
universities, state and municipal offices and others who have been active in
growing manufacturing competitiveness, says David Danielson, DOE assistant
secretary for energy efficiency and renewable energy.

COMENTARIO: Debemos tener muy en cuenta el hecho de que la nica

solucin a largo plazo para tantos problemas ambientales es la
tecnologa de energa limpia, la aplicacin continua de una estrategia
ambiental preventiva integrada a los procesos, productos y servicios
para aumentar la eficiencia global y reducir los riesgos para los seres
humanos y el medio ambiente.