CERES :: Browsing by Author "Jolly, Mark R."

Browsing by Author "Jolly, Mark R."

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Open Access
A bespoke carbon footprint framework to set the path towards Net Zero in foundries
(Elsevier, 2024) Cox, Rylan; Pagone, Emanuele; Jolly, Mark R.; Salonitis, Konstantinos; Birch, Tim
A bespoke carbon footprint framework for the metal casting industry is presented to enable swifter carbon accounting of foundries and identify energy and carbon footprint hotspots to support the drive towards Net Zero goals. Many manufacturing enterprises in the United Kingdom and Europe are already struggling to maintain financial competitiveness as well as drive towards a sustainable shift, particularly SMEs. This framework is to help alleviate the pressure on the industry by providing an outside tool to direct companies to sustainable solutions. This paper validates such framework breaking down the environmental footprint of ferrous products through energy and material profiles of sand casting processes in two real UK foundries identified as “A” and “B”. During environmental visits, it was established that Foundry A emitted an average of 41700 tons of CO2 annually and Foundry B 1400 tons. The framework developed to estimate the melting process energy (to be, then, converted into carbon footprint) predicted with about 15% accuracy the actual data. Furthermore, the framework can be expanded and improved on for its accuracy and into other processes within the casting process including melting, core and mould making, pouring sand reclamation, ancillaries and fettling.
Open Access
A conceptual assessment framework for sustainability in the foundation industries
(Elsevier, 2024) Litos, Lampros; Paddea, Sanjooram; Salonitis, Konstantinos; Jolly, Mark R.
Foundation industries in the UK are in constant pursuit of better technological solutions to enhance materials conversion efficiency and supply chain economies of scale. However, sustainable materials and strategies to conserve resources and better utilize waste streams tend to be ever more challenging to achieve when technological advances fall short in being widely adoptable by companies. Knowledge and technology transfer across multiple companies within the same sector (for example, construction materials production) or across seemingly common core processes (such as size reduction or furnaces) must be achieved for sustainability efforts to achieve economies of scale. Part of the reason why this is a difficult endeavor is the lack of visibility of the steps and drivers involved in a circular economy context with a view to achieve scale. Materials and technologies that could help foundation industries become more sustainable are being examined through the introduction of a novel framework that could help companies and policy makers understand where the opportunities exist. In this paper, the authors describe the design and development of the framework and offer examples drawn from an ongoing research and innovation project in foundation industries.
Open Access
A critical review of the decarbonisation potential in the U.K. cement industry
(MDPI, 2025-01-10) Sherif, Ziyad; Sarfraz, Shoaib; Jolly, Mark R.; Salonitis, Konstantinos
As urbanisation and infrastructure development continue to drive rising cement demand, the imperative to significantly reduce emissions from this emissions-intensive sector has become increasingly urgent, especially in the context of global climate goals such as achieving net zero emissions by 2050. This review examines the status, challenges and prospects of low-carbon cement technologies and mitigation strategies through the lens of the U.K. cement industry. A mixed-methods approach was employed, combining structured literature searches across academic databases with analyses of industry reports, market data and technological roadmaps to ensure a comprehensive evaluation. Following an outline of cement production, resource flows and the sector’s landscape in the U.K., the review delves into an array of decarbonisation pathways. This includes deploying the best available technologies (BATs), fuel switching, carbon capture utilisation and storage (CCUS), clinker substitution and low-carbon cement formulations. A critical assessment is provided on the technological readiness, costs, resource availability considerations and scalability aspects governing the widespread implementation prospects of these approaches within the U.K. cement industry. Furthermore, this study proposes a roadmap that considers priority avenues and policy needs essential for facilitating the transition towards sustainable cement production aligned with the U.K.’s net zero obligations by 2050. This evaluation contributes significantly to the ongoing decarbonisation discourse by holistically mapping technological solutions and strategic imperatives tailored to the unique challenges and opportunities presented by the U.K. cement sector.
Open Access
Assessment of casting filling by modeling surface entrainment events using CFD
(The Minerals, Metals and Materials Society, 2010-05-31) Reilly, C.; Jolly, Mark R.; Green, N. R.; Gebelin, J. C.
The reliability of cast components is dependent on the quality of the casting process. During this highly transient filling phase the prevention of free surface turbulence and consequential oxide entrainment is critical to ensure the mechanical integrity of the component. Past research has highlighted a number of events that lead to entrainment of surface oxides. Using FLOW-3D, flow structures that result in surface entrainment events have been simulated and an algorithm developed that allows entrainment and defect motion to be tracked. This enables prediction of the quantity and motion of oxide film generated from each event. The algorithm was tested experimentally and compared to experimental data from previously published work. A quantitative criterion is proposed to assess the damage of each type of event. Complete running systems have also been studied to understand how they could be assessed for quality of filling based on the flows within them.
Open Access
Automatically weighted high-resolution mapping of multi-criteria decision analysis for sustainable manufacturing systems
(Elsevier, 2020-02-01) Pagone, Emanuele; Salonitis, Konstantinos; Jolly, Mark R.
A common feature of Multi-Criteria Decision Analysis (MCDA) to evaluate sustainable manufacturing is the participation (to various extents) of Decision Makers (DMs) or experts (e.g. to define the importance, or “weight”, of each criterion). This is an undesirable requirement that can be time consuming and complex, but it can also lead to disagreement between multiple DMs. Another drawback of typical MCDA methods is the limited scope of weight sensitivity analyses that are usually performed for one criterion at the time or on an arbitrary basis, struggling to show the “big picture” of the decision making space that can be complex in many real-world cases. This work removes all the mentioned shortcomings implementing automatic weighting through an ordinal combinatorial ranking of criteria objectively set by four pre-defined weight distributions. Such solution provides the DM not only with a fast, rational and systematic method, but also with a broader and more accurate insight into the decision making space considered. Additionally, the entropy of information in the criteria can be used to adjust the weights and emphasise the differences between potentially close alternative
Open Access
Benchmarking of energy consumption and CO2 emissions in cement production: a case study
(Springer, 2024-02-02) Sarfraz, Shoaib; Sherif, Ziyad; Jolly, Mark R.; Salonitis, Konstantinos
In the pursuit of economic growth and value creation, foundation industries including cement, metals, glass, chemicals, paper, and ceramics face formidable challenges related to energy usage, emissions, and resource consumption in their manufacturing operations, all while striving to achieve ambitious Net Zero carbon and green targets. To overcome these challenges and propel sustainable progress, benchmarking emerges as a powerful ally. This study performs a benchmarking analysis of energy use and CO2 emissions for a UK cement plant as well as best available techniques (BAT) investigation to identify opportunities for performance improvement in crucial areas such as energy usage and environmental sustainability. The research utilises industrial data from a 2850 tonne per day capacity dry process cement plant. Key energy and emissions parameters, including thermal and electrical energy intensity, recovered energy and CO2 intensity, are computed per tonne of cement produced along with capacity utilisation across major process stages including raw material grinding, clinkerisation, and cement grinding. Comprehensive data sourced directly from the manufacturer is compared against literature benchmarks for global averages and best practices. Although surpassing global average values, the plant lags European best practices across all metrics, signalling room for substantial improvement. Assessment of relevant BATs for the cement industry reveals prospects to integrate vertical roller mills for cement grinding and use Organic Rankine Cycle (ORC) at the clinkerisation stage. Adopting these techniques could reduce the electrical energy intensity of clinkerisation by 51% and cement grinding electrical intensity by 30%, surpassing benchmarks. While limited to a single cement plant, the study provides a standardised methodology that could be replicated across foundation industries to enable performance tracking and highlight efficiency gaps. The benchmarking approach developed can guide the implementation of energy conservation measures and the adoption of best practices by the cement industry to reduce its carbon footprint.
Open Access
The capability enhancement of aluminium casting process by application of the novel CRIMSON method
(Wiley, 2011-04-19) Dai, Xiaojun; Jolly, Mark R.; Zeng, Binxu
The conventional foundry not only frequently uses batch melting, where the aluminium alloys are melted and held in a furnace for long time, sometimes as long as a complete shift, but also uses the gravity sand casting process where the molten aluminium alloys are transferred using a ladle from furnace to pour station and are poured into a mould. During the filling of the mould, the turbulent nature of the liquid metal gives rise to massive entrainment of the surface oxide films which are the subsequently trapped into the liquid and act as micro cracks. Also the long exposure time of the liquid surface to the surrounding environment during melting, transferring and filling will increase the level of hydrogen absorption from the atmosphere. The abovementioned factors are often the main reasons for casting defect generation. In this paper the novel CRIMSON aluminium casting method is introduced which has a number of advantages. Instead of gravity filling method, it uses the single shot upcasting method to realize the rapid melting and rapid counter-gravity-filling mould operations which reduce the contact time between the melt and environment thus reducing the possibility of defect generation. Another advantage is the drastic reduction of energy consumption due to shortened melting and filling time. A simulation software, FLOW-3D, is used to compare this new method with the conventional gravity casting process. A tensile bar case is used as a sample to simulate the filling process.
Open Access
Caught in the act: The structural pathway of liquid metals to vitrification monitored in situ by synchrotron X-ray diffraction.
(Cranfield University, 2021-09) Stiehler, Martin E.; Georgarakis, Konstantinos; Jolly, Mark R.
When a metallic melt is undercooled fast enough below its liquidus temperature, crystallisation can be avoided and a metallic glass, i.e. a metallic solid with amorphous structure, be formed. This kind of solidification is called vitrification. The prerequisites for this phenomenon are still not clear. An extensive review of the available relevant literature was carried out. To reveal the structural changes taking place at the atomic scale during undercooling and vitrification, data obtained by ultrafast synchrotron X-ray diffraction during aerodynamic-levitation experiments of different metallic-glass forming liquids was analysed. The complete pathway from temperatures well above the liquidus temperature during undercooling and vitrification down to temperatures well below the glass-transition temperature Tg was studied. During undercooling, a non-linear evolution of structural metrics in real as well as in reciprocal space takes place. Especially the height of the first maximum in the structure factor can be described by a structural analogue to the Curie-Weiss law. This behaviour was also found in published data re-analysed here. Indications of universal behaviour among the investigated alloys below a certain temperature as well as for a liquid-liquid crossover in Ti₄₀Cu₃₄Pd₁₄Zr₁₀Sn₂ were found. Small differences in the temperature dependence of the structural behaviour among the different alloys are possibly related to their different glass-forming abilities. To facilitate the analysis of the real-space structure the novel concept of the anti-shell was introduced. Temperature affects different length scales differently. Below Tg the structural behaviour is dominated by the Debye-Waller factor as well as by normal thermal-expansion behaviour. Above Tg an apparent negative thermal expansion of the first nearest-neighbour distance can be attributed to the influence of the structure-forming processes. In addition to short- and medium-range order, a third structural range for distances beyond the third nearest-neighbour is proposed. A disordering of the atomic structure of metallic glasses by the introduction of further alloying elements, facilitated by emergent effects among the components, could be demonstrated. The importance of the influence of global electronic interactions on structure formation was shown as well as their limitation to distances beyond the third nearest-neighbour.
Open Access
Cellulose filaments derived from dissolution and spinning of paper sludge nanofibers using an ionic liquid Item
(Cranfield University, 2020-04-17 09:08) Adu, Cynthia; Zhu, Chenchen; Jolly, Mark R.; Oksman, Kristiina; Eichhorn, Stephen J.; Richardson, Robert
Dataset posted on 2020-04-17, 10:08 authored by Cynthia Adu, Chenchen Zhu, Mark Jolly, Kristiina Oksman, Stephen J. Eichhorn, Robert M. Richardson, Kevin D. Potter This data set contains results from the experimental test conducted to dissolve and spin cellulose nanofibres into filaments. The CNF was derived from paper mill sludge by mechanical grinding and dissolved in ionic liquid at 9 and 12% CNF concentration. Fibre pinning was conducted by dry-jet wet spinning method to produce filaments with average tensile strength of 19 GPa and 26 GPa, and modulus of 223 MPa and 282 MPa respectively. Enclose is the data from the tensile tests, rheology of the spinning solution and the filament orientation obtained from the wide angle x-ray of the filament.
Open Access
The challenges for energy efficient casting processes
(Elsevier, 2016-02-19) Salonitis, Konstantinos; Zeng, Binxu; Mehrabi, Hamid Ahmad; Jolly, Mark R.
Casting is one of the oldest, most challenging and energy intensive manufacturing processes. A typical modern casting process contains six different stages, which are classified as melting, alloying, moulding, pouring, solidification and finishing respectively. At each stage, high level and precision of process control is required. The energy efficiency of casting process can be improved by using novel alterations, such as the Constrained Rapid Induction Melting Single Shot Up-casting process. Within the present study the energy consumption of casting processes is analyzed and areas were great savings can be achieved are discussed. Lean thinking is used to identify waste and to analyse the energy saving potential for casting industry.
Open Access
Comparison of the environmental impact of the crimson process with normal sand casting process
(Cranfield University Press, 2013-09-19) Zeng, Binxu; Salonitis, Konstantinos; Jolly, Mark R.
The CRIMSON process is an alternative process to conventional casting that can be used for small to medium batch sizes. The aim of this process are to improve the casting quality and reduce the energy consumption within light-metal casting industry. Nowadays, the energy efficiency becomes more and more important. This is not only about the cost of the production, but also about the environmental effect. In this paper, the CRIMSON process will be compared with the conventional sand casting process. The Life cycle assessment (LCA) method will be used to assess the environmental impact of both casting processes.
Open Access
Comparison of the environmental impact of the CRIMSON process with normal sand casting process
(2013-09-02T00:00:00Z) Zeng, Binxu; Salonitis, Konstantinos; Jolly, Mark R.; Shehab, Essam; Ball, Peter D.; Tjahjono, Benny
The CRIMSON process is an alternative process to conventional casting that can be used for small to medium batch sizes. The aim of this process are to improve the casting quality and reduce the energy consumption within light-metal casting industry. Nowadays, the energy efficiency becomes more and more important. This is not only about the cost of the production, but also about the environmental effect. In this paper, the CRIMSON process will be compared with the conventional sand casting process. The Life cycle assessment (LCA) method will be used to assess the environmental impact of both casting processes.
Open Access
A computational framework towards energy efficient casting processes
(Springer, 2018-12-01) Papanikolaou, Michail; Pagone, Emanuele; Salonitis, Konstantinos; Jolly, Mark R.; Makatsoris, Makatsoris
Casting is one of the most widely used, challenging and energy intensive manufacturing processes. Due to the complex engineering problems associated with casting, foundry engineers are mainly concerned with the quality of the final casting component. Consequently, energy efficiency is often disregarded and huge amounts of energy are wasted in favor of high quality casting parts. In this paper, a novel computational framework for the constrained minimization of the pouring temperature is presented and applied on the Constrained Rapid Induction Melting Single Shot Up-Casting (CRIMSON) process. Minimizing the value of the pouring temperature can lead to significant energy savings during the melting and holding processes as well as to higher yield rate due to the resulting reduction of the solidification time. Moreover, a multi-objective optimization component has been integrated into our scheme to assist decision makers with estimating the trade-off between process parameters.
Open Access
Continuous and sustainable cellulose filaments from ionic liquid dissolved paper sludge nanofibres
(Elsevier, 2020-10-03) Adu, Cynthia; Zhu, Chenchen; Jolly, Mark R.; Richardson, Robert M.; Eichhorn, Stephen J.
The textile industry is resource intensive, which has a significant impact on global emissions and waste pollution. To meet the demand of textiles over a third of fibres used in manufacturing are sourced from fossil fuels. As the global demand for textiles continues to grow, manufacturers have having to seek innovative approaches to providing sustainable regenerative cellulose fibres. However, the latest climate change pressures on the textile industry has uncovered grave environmental issues associated with traditional regenerative cellulose production such as the viscose manufacturing process. The viscose process the required intensive use of hazardous chemicals which leads to water pollution and ecotoxicity. In addition, if forestry products are unsustainably sourced for the viscose production this can lead to resource scarcity and deforestation. To provide a holistic solution for mitigating these challenges this study uses the by-products of paper manufacturing dissolved in an ionic liquid to produce regenerated cellulose filaments. Paper mill sludge (PMS) is a cellulosic by-product typically used on animal bedding and land spreading. The material has been dissolved in an ionic liquid - 1-ethyl-3-methylimidazolium diethyl phosphate - with the aid of a co-solvent dimethyl sulfoxide (DMSO) - and spun into continuous filaments for textile production. The mechanical properties of paper sludge filaments are found to be competitive with commercial viscose, which is promising for their drop-in replacement. It is also demonstrated that by increasing the concentration of the PMS from 9% to 12.4%, an improvement of the filament properties can be achieved; an increase in modulus from ~19 GPa to ~ 26 GPa and ~ 223 MPa to ~ 282 MPa. These values are shown to be competitive with other commercial, less sustainable, regenerated cellulose fibres
Open Access
Defect minimisation in vacuum assisted plaster mould investment casting through simulation of high value aluminium alloy components
(Springer, 2023-02-09) Pagone, Emanuele; Jones, Christopher A.; Forde, John; Shaw, William; Jolly, Mark R.; Salonitis, Konstantinos
Vacuum-assisted plaster mould investment casting is one of the best available processes to manufacture ultra-high complexity castings for the aerospace and defence sectors. In light of the emerging cross-sectoral manufacturing industry digitalisation, process simulation appears as a very important tool to improve casting yield, reduce metallurgical scrap, and reduce lead time to new product introduction. Considering the unique aspects and the level of customisation of the process system, this work will present a Computational Fluid Dynamics-based simulation tool with bespoke settings (that include thermophysical properties). Optimal fill and solidification parameters are identified for a representative geometry able to describe a variety of very complex, high-value aluminium alloy components through an iterative process.
Open Access
Design optimisation of the feeding system of a novel counter-gravity casting process
(MDPI, 2018-10-11) Papanikolaou, Michail; Pagone, Emanuele; Georgarakis, Konstantinos; Rogers, Keith; Jolly, Mark R.; Salonitis, Konstantinos
The appropriate design of feeders in a rigging system is critical for ensuring efficient compensation for solidification shrinkage, thus eliminating (shrinkage-related) porosity and contributing to the production of superior quality castings. In this study, a multi-objective optimisation framework combined with Computational Fluid Dynamics (CFD) simulations has been introduced to investigate the effect of the feeders’ geometry on shrinkage porosity aiming to optimise casting quality and yield for a novel counter-gravity casting process (CRIMSON). The weighted sum technique was employed to convert this multi-objective optimisation problem to a single objective one. Moreover, an evolutionary multi-objective optimisation algorithm (NSGA-II) has been applied to estimate the trade-off between the objective functions and support decision makers on selecting the optimum solution based on the desired properties of the final casting product and the process characteristics. This study is one of the first attempts to combine CFD simulations with multi-objective optimisation techniques in counter-gravity casting. The obtained results indicate the benefits of applying multi-objective optimisation techniques to casting processes
Open Access
Designing a circular business model from industrial by-products: A case study on paper mill sludge
(Cranfield University, 2019-10) Adu, Cynthia Ediabai; Jolly, Mark R.; Eichhorn, Stephen
The circular economy (CE) emphasises the optimisation of resource yields by keeping products, components and materials at their highest utility and value. This recently popularised concept has created awareness within businesses, government and policymakers. However, there is a discourse that the concept lacks scientific rigour and has primarily been led by practitioners such as policy makers, social scientists and business consultants. Resources in the CE concept are referred to as biological nutrients and technical nutrients. Based on the CE resource recovery model, biological nutrients such as organic waste/by-products are expected to return to the system. However, the current waste management sector is not equipped with how to innovate and/or create value from resources termed as waste/by-products. Whilst CE is a commendable strategy with insightful case studies, the philosophy currently lacks robust design guidance that can provide businesses with the tools and tactics required to meet the agenda. Therefore, this EngD research applies design thinking innovation methodology to an existing business faced with the challenge of adopting a circular business model for resource recovery. The EngD research is based on Ecoganix, an organic waste treatment company. Ecoganix manages Paper Mill Sludge (PMS), a by-product derived from the waste-water treatment of paper mills. In the UK, a million tonnes of PMS is currently produced annually. The management of PMS is an environmental challenge and the second highest cost for the sector after energy consumption. The PMS is collected by Ecoganix from 7 paper mills in the UK for use as soil improvement on farm land . The current management system of PMS is unsustainable and short-term. Moreover, the market is highly competitive due to increasing recycling rates and competitive pricing. Nonetheless, this material PMS is rich in organic cellulose fibres and inorganic minerals. Thus, a design thinking methodology is used to create new value streams of materials from this byproduct...[cont.]
Open Access
Developing fiber and mineral based composite materials from paper manufacturing by-products
(Springer, 2017-04-27) Adu, Cynthia; Jolly, Mark R.
Developing valuable materials from the by-products of paper industry can help to address some environmental and economic issues associated with traditional synthetic composites. Particularly, the management of paper mill sludge (PMS) waste remains an economic and environmental challenge for the pulp and paper industry. 11 million tons of PMS is generated annually in Europe from the wastewater treatment (WWT) process of paper mills. PMS is mostly used in low value applications. However, PMS contains fibers and minerals with physio-chemical properties that exhibit a high potential to substitute some conventional materials in other industries. The research presented in this paper aims to explore new directions for further investigation on PMS material applications by reviewing the literature on PMS materials and subsequently characterizing sludge from 6 different mills. The study shows the technical feasibility, opportunities and technological readiness of fiber and mineral based composites obtained from PMS, such as; cementitious products, polymer reinforcement and fiberboards.
Open Access
The development of a tool to promote sustainability in casting processes
(Elsevier, 2016-11-02) Pagone, Emanuele; Jolly, Mark R.; Salonitis, Konstantinos
The drive of the manufacturing industry towards productivity, quality and profitability has been supported in the last century by the availability of relatively cheap and abundant energy sources with limited focus on the minimisation of energy and material waste. However, in the last decades, more and more stringent regulations aimed at reducing pollution and consumption of resources have been introduced worldwide and in particular in Europe. Consequently, a highly mature and competitive industry like foundry is expecting challenges that an endeavour towards sustainability can turn into significant opportunities for the future. A tool to undertake a systematic analysis of energy and material flows in the casting process is being developed. An overview of the computer program architecture is presented and its output has been validated against real-world data collected from foundries.
Open Access
Effect of batch initial velocity on the glass furnace efficiency
(WIley, 2014-01-10) Soleimanian, Nasim; Jolly, Mark R.; Dearn, Karl; Brinkman, Oliver; Brinkman, William
Glass manufacturing is a heat intensive process. There is a direct coloration between the batch distribution techniques and the furnace energy consumption, productivity, and quality of the glass manufactured. All four major segments (float, container, fibre, and specialty glasses) would benefit from using an optimised batch distribution technique where possible. Oscillating batch chargers (OBC) have been in use since the early 70s, despite their superior batch shape, coverage, and in turn positive effects on the energy consumption (Soleimanian, TMS 2013) and productivity of the furnace they are almost exclusively used in container glass manufacturing. The OBC’s main difference compared with other charging methods is its ability to directly influence the batch initial velocity. This paper reports on results achieved in two CFD models (in Flow 3D and GFM) used to study effect of the machine on the overall energy consumption in the doghouse and the melt space.

Browsing by Author "Jolly, Mark R."

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