• Energy Research

Abstract Safety Improvement of engineering processes, especially Oil & Gas operations, has gained a lot of attention during the last decades. This fundamental vision results in risk remediation programs, minimizing the risks of failure, and reducing the associated costs for operation and maintenance. As failures may represent serious threats for both humans and the environment, a comprehensive tool is required to employ maintenance and avoid immoderate dangerous consequences. Traditional risk frameworks mainly include estimation approaches, such as Fault Tree (FT) and Event Tree (ET), producing more simplified models than other tools, such as Bayesian inference. The present work aimed at developing an advanced Risk-Based Maintenance (RBM) methodology for prioritizing maintenance operations, by addressing associated uncertainties through the accident modelling of the process. For this purpose, a Hierarchical Bayesian Approach (HBA) is applied to estimate the failure probabilities of each component while a Failure Mode, Effects and Criticality Analysis is performed to assess the severity. With Markov Chain Monte Carlo simulation from likelihood function and prior distribution, the HBA is capable of incorporating the fluctuations and uncertainties associated with operational data including the variability between the source of data and the correlation of observations. Lastly, to make a meaningful difference between different kinds of risk consequences, whether the risk has a direct or indirect loss, the cost of failures of components is accounted for. To demonstrate the application of the methodology, a Natural Gas Reduction and Measuring Station (NGRMS) is taken into account as a case study. The outcome of the case study proofed that PTG and pump are the most failures sensitive components among other if they being left unattended in the operation with an average number of failure occurrences of 67 and 45; While the THT pipelines and THT tank are less sensitive for being considered for major maintenance request with almost average of 5 times in their lifetime. The proposed method can be exploited by maintenance engineers, asset managers, and policymakers to reduce the downtime periods as well as the risks of on-going operations.

The foundry industry is regarded as one of the most energy-intensive industrial sector due to its energy consumption up to 9 MWh/ton of produced metal. As a result, many companies are trying to increase the energy efficiency of their foundry plants. Since many energy-saving technologies are proposed by manufacturers and the literature, choosing the most appropriate one is a difficult task. Moreover, being updated with the available energy-saving solutions is complicated because of the quick technology advances. Consequently, this paper aims at investigating the recent and future opportunities and investments for reducing the energy consumptions of the technologies of Italian foundry companies. Additionally, it aims at presenting a list of available technological solutions validated by Italian experts. To this end, the Energy Audits developed by 231 plants were analyzed to extract the implemented and planned interventions. Furthermore, the economic data available within the Energy Audits were studied to determine the advantages of a given technological solutions compared to the others. It emerged that the companies are strongly investing in increasing the efficiency of the auxiliary systems such as compressors and motors. The outcomes of this study can assist both researchers and energy managers in choosing the most appropriate energy-saving solutions.

The cement industry is highly energy-intensive, consuming approximately 7% of global industrial energy consumption each year. Improving production technology is a good strategy to reduce the energy needs of a cement plant. The market offers a wide variety of alternative solutions; besides, the literature already provides reviews of opportunities to improve energy efficiency in a cement plant. However, the technology is constantly developing, so the available alternatives may change within a few years. To keep the knowledge updated, investigating the current attractiveness of each solution is pivotal to analyze real companies. This article aims at describing the recent application in the Italian cement industry and the future perspectives of technologies. A sample of plant was investigated through the analysis of mandatory energy audit considering the type of interventions they have recently implemented, or they intend to implement. The outcome is a descriptive analysis, useful for companies willing to improve their sustainability. Results prove that solutions to reduce the energy consumption of auxiliary systems such as compressors, engines, and pumps are currently the most attractive opportunities. Moreover, the results prove that consulting sector experts enables the collection of updated ideas for improving technologies, thus giving valuable inputs to the scientific research.

The glass industry is highly energy-intensive, consuming approximately 500–700 million GJ each year. Replacing inefficient equipment with better-performing equipment is a good strategy to reduce the energy consumption of a glass plant. Since there are many alternative solutions, the choice of which technological improvement to implement is usually difficult. Therefore, a review of solutions to reduce energy consumption in a glass plant is pivotal. The literature offers similar studies, but they are not sufficiently up-to-date and do not represent the actual state of the art, which should be updated. Thus, this paper aims to provide an updated list of alternative solutions, clustering them into different categories (e.g., the process stage). Moreover, this paper investigates the current applicability of energy-saving solutions in Italy. Specifically, a sample of 103 Italian companies is considered and the type of interventions that the companies recently implemented or that they intend to adopt is analyzed. Quantitative statistical and economic analyses were conducted to highlight the most popular solutions and determine their cost-effectiveness. The results show that most interventions consist of replacing machinery with more efficient ones, mainly in auxiliary systems (132 out of 426). The outcome of this paper could represent a guide to select energy-saving solutions.

Logistics is a vital activity for the economic growth of an organization as it manages the flow of materials and information within, into, and out of the organization, as well as reverse flow. Like many other industrial processes, logistics has also been impacted by the rise of Industry 4.0 technologies, which has highlighted the significance of Logistics 4.0. However, Logistics 4.0 is mainly focused on economic benefits, while overlooking environmental and social concerns. To address this, a method is proposed that takes into account the three goals of sustainable development when selecting the best technology for internal material handling activities. Firstly, a comprehensive literature review was conducted to examine the application of 4.0 technologies in logistics processes and their impact on economic, environmental, and social sustainability. Secondly, based on the findings of the review, a three-level analytic hierarchy process was proposed to identify the optimal 4.0 technology for internal logistics. To demonstrate the practicality of the proposed method, it was tested on three companies. The results showed that additive manufacturing, exoskeletons, and collaborative robots are the most suitable options for achieving sustainable development goals within Logistics 4.0.

The conveniency between remanufacturing a single mechanical product and its new production is a highly investigated topic across various disciplines, including supply chain management. To this end, a comparison was made among three different configurations of the supply chain network: the traditional network for new production, the network with remanufacturing and direct interaction between customer and manufacturer, and the network with remanufacturing and indirect interaction between customer and manufacturer through a distribution center. The evaluation of scenarios for the remanufacturing conveniency of remanufacturing was conducted from both an economic and energetic perspective, generating 10'000 cases using the Sobol quasi-random low-discrepancy sequence. The generation was carried out for both economic and energetic analyses for three types of materials, namely steel, aluminum, and titanium, for which complete datasets are provided: Steel_EconomicAnalysis.xlsx: dataset for economic analysis for the remanufacturing conveniency of mechanical products in steel Steel_EnergeticAnalysis.xlsx: dataset for energetic analysis for the remanufacturing conveniency of mechanical products in steel Aluminum_EconomicAnalysis.xlsx: dataset for economic analysis for the remanufacturing conveniency of mechanical products in aluminum Aluminum_EnergeticAnalysis.xlsx: dataset for energetic analysis for the remanufacturing conveniency of mechanical products in aluminum Titanium_EconomicAnalysis.xlsx: dataset for economic analysis for the remanufacturing conveniency of mechanical products in titanium Titanium_EnergeticAnalysis.xlsx: dataset for energetic analysis for the remanufacturing conveniency of mechanical products in titanium