陶瓷企业低碳制造系统模式及评估与建模方法
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摘要
全球气候变化问题是工业化进程遇到的新挑战。节能减排,减少二氧化碳排放,实施低碳制造战略是制造工业技术及产业发展的重要方向。陶瓷工业是我国的传统行业,同时也是高消耗、高排放的重点行业。在陶瓷工业领域,推行低碳制造模式,从陶瓷产品全生命周期,包括原材料获取、能源生产、产品设计、制造、使用到报废处理等环节,实施碳排放的源头控制和减量化战略具有必要性和迫切性。本论文围绕陶瓷制造企业低碳制造系统模式及若干共性方法展开研究,将为我国陶瓷工业发展和推广低碳制造模式,实现节能减排提供理论和方法参考,具有重要的研究价值。
首先,对陶瓷制造企业低碳制造系统模式进行了研究。在分析我国陶瓷企业高能耗、高物耗、高排放的现状以及陶瓷产品生命周期过程特征的基础上,提出陶瓷企业低碳制造系统的概念,并从物料流、能量流的角度来阐述陶瓷企业低碳制造系统的内涵;建立一种面向陶瓷产品生命周期过程,包含目标层、节能减排策略层、生命周期层、支撑层等四层结构的陶瓷企业低碳制造系统框架;建立一种以碳排放、时间、质量、成本为目标的陶瓷企业低碳制造系统决策框架模型,为陶瓷企业低碳制造系统实施决策分析提供一种方法。
其次,面向所提出的陶瓷企业低碳制造系统模式的实施需求,对陶瓷产品生命周期碳排放特性分析与碳足迹评估方法进行了研究。基于生命周期理论,总结并计算了我国常用一次能源、二次能源及陶瓷生产常用物料的碳排放系数;建立了陶瓷企业物料平衡模型和能源平衡模型,为陶瓷生产过程中各种物料及能源消耗量的分析和计算提供了方法;基于物料与能源的碳排放系数以及物料与能源消耗平衡模型,提出一种新的陶瓷产品碳足迹计算方法,并将其应用于卫生陶瓷产品的碳足迹评价。
再次,针对陶瓷企业作为典型流程型行业的特点以及陶瓷企业低碳制造过程建模的需求,基于模糊Petri网的基本原理,综合考虑运行状态的连续性及离散状态对连续过程的影响,提出了陶瓷企业低碳制造过程建模方法,并给出了形式化定义规则,建立了陶瓷企业生产过程模糊Petri网框架模型及相关的嵌套子模型。以典型的陶瓷烧成系统为例说明验证了模型的应用。
所提出的陶瓷企业低碳制造系统模式及评价与建模方法在江西景德镇某建陶有限公司进行了初步应用,取得了良好的效果,为陶瓷企业实施低碳制造提供了参考与指导。
Low-carbon manufacturing is a new manufacturing model, committing to the efficient use of energy and resources, thus reducing the carbon emission intensity of the whole life cycle, and emphasizing the carbon emissions reduction and control in the whole life cycle, from the raw material acquisition, energy production, product design, manufacture, use to scrap. Low-carbon is one fundamental way to relieve the pressure of national manufacturing, meeting the national responses to climate change and major projects, the development of circular economy, the implementation of energy-saving and emission-reduction development strategies. For the characteristics of the ceramic enterprises, the high energy consumption, high materials consumption and high emission, the promotion of the implementation of low-carbon manufacturing system model is very significant. This paper is proposed based on a series of scientific problems encountered in the implementation of low-carbon manufacturing system model in ceramic enterprises, and studies the low-carbon manufacturing system model of ceramic enterprises and supported technology.
Firstly, based on the analysis of the current situation with high energy consumption, high emission of ceramic enterprises, the low-carbon manufacturing system of ceramic enterprises is proposed. From the view of the material flow, energy flow, the connotation of the low-carbon manufacturing system of ceramic enterprises is expounded. The overall framework of low-carbon manufacturing system model of ceramic enterprises is established, focusing on the whole life cycle of ceramic product and including four-story structure, such as the goal layer, energy conservation strategy layer, the life cycle layer and support layer, then focus on the analysis of the goal layer, energy conservation strategy layer, the life cycle layer and support layer respectively. For providing a method for decision analysis on the implementation of low-carbon manufacturing system of ceramic enterprises, a decision-making framework model of low-carbon manufacturing system of ceramic enterprises is established with the target of carbon emissions, time, quality and cost.
Secondly, based on the proposed low-carbon manufacturing system model of ceramic enterprises, the carbon emissions characteristics of ceramic product life cycle and the assessment techniques for carbon footprint are studied. Recalling the concept of carbon footprint and the basic theory of carbon footprint methods and life cycle assessment evaluation methods, and calculating the carbon emission factors of primary energy and secondary energy used in China and common materials of ceramic production, based on the theory of life cycle. The material balance model and energy balance model of ceramic enterprises are established for the quantifying the material and energy consumption of ceramic enterprises. Based on the carbon emissions factors of material and energy and the balance models of material and energy consumption, a new calculation method of carbon footprint of ceramic products is proposed, then, used to the analysis of carbon footprint of ceramic products.
Thirdly, for the characteristics that ceramic enterprises are the typical process-based industries and the modeling requirement of low-carbon manufacturing of ceramic enterprises, and according to the basic theory of fuzzy Petri nets, seizing the continuity of its running state and the effects of its discrete state on continuous process, the fuzzy Petri nets is applied to the modeling of low-carbon manufacturing process of ceramic enterprises successfully. This paper introduces the basic principles of Petri nets and gives the formal definition and rule description. According to the characteristics of ceramic production process, the fuzzy Petri nets framework model of production of enterprises and associated nested sub-models are established. The production process, resource allocation, waste heat recycling can be integrated by this model. For the foundation of the implementation of low-carbon manufacturing in enterprises, illustrating the application of this model with an example, the typical ceramic firing system, simulating the dynamic behavior of energy consumption of ceramic enterprises and highlighting the value of the model.
Finally, the low-carbon manufacturing system of ceramic enterprises and key technology are preliminarily applied in a ceramic company in Jiangxi, achieving good results and providing guidance and reference to the implementation of low-carbon manufacturing in ceramic enterprises.
首先,对陶瓷制造企业低碳制造系统模式进行了研究。在分析我国陶瓷企业高能耗、高物耗、高排放的现状以及陶瓷产品生命周期过程特征的基础上,提出陶瓷企业低碳制造系统的概念,并从物料流、能量流的角度来阐述陶瓷企业低碳制造系统的内涵;建立一种面向陶瓷产品生命周期过程,包含目标层、节能减排策略层、生命周期层、支撑层等四层结构的陶瓷企业低碳制造系统框架;建立一种以碳排放、时间、质量、成本为目标的陶瓷企业低碳制造系统决策框架模型,为陶瓷企业低碳制造系统实施决策分析提供一种方法。
其次,面向所提出的陶瓷企业低碳制造系统模式的实施需求,对陶瓷产品生命周期碳排放特性分析与碳足迹评估方法进行了研究。基于生命周期理论,总结并计算了我国常用一次能源、二次能源及陶瓷生产常用物料的碳排放系数;建立了陶瓷企业物料平衡模型和能源平衡模型,为陶瓷生产过程中各种物料及能源消耗量的分析和计算提供了方法;基于物料与能源的碳排放系数以及物料与能源消耗平衡模型,提出一种新的陶瓷产品碳足迹计算方法,并将其应用于卫生陶瓷产品的碳足迹评价。
再次,针对陶瓷企业作为典型流程型行业的特点以及陶瓷企业低碳制造过程建模的需求,基于模糊Petri网的基本原理,综合考虑运行状态的连续性及离散状态对连续过程的影响,提出了陶瓷企业低碳制造过程建模方法,并给出了形式化定义规则,建立了陶瓷企业生产过程模糊Petri网框架模型及相关的嵌套子模型。以典型的陶瓷烧成系统为例说明验证了模型的应用。
所提出的陶瓷企业低碳制造系统模式及评价与建模方法在江西景德镇某建陶有限公司进行了初步应用,取得了良好的效果,为陶瓷企业实施低碳制造提供了参考与指导。
Low-carbon manufacturing is a new manufacturing model, committing to the efficient use of energy and resources, thus reducing the carbon emission intensity of the whole life cycle, and emphasizing the carbon emissions reduction and control in the whole life cycle, from the raw material acquisition, energy production, product design, manufacture, use to scrap. Low-carbon is one fundamental way to relieve the pressure of national manufacturing, meeting the national responses to climate change and major projects, the development of circular economy, the implementation of energy-saving and emission-reduction development strategies. For the characteristics of the ceramic enterprises, the high energy consumption, high materials consumption and high emission, the promotion of the implementation of low-carbon manufacturing system model is very significant. This paper is proposed based on a series of scientific problems encountered in the implementation of low-carbon manufacturing system model in ceramic enterprises, and studies the low-carbon manufacturing system model of ceramic enterprises and supported technology.
Firstly, based on the analysis of the current situation with high energy consumption, high emission of ceramic enterprises, the low-carbon manufacturing system of ceramic enterprises is proposed. From the view of the material flow, energy flow, the connotation of the low-carbon manufacturing system of ceramic enterprises is expounded. The overall framework of low-carbon manufacturing system model of ceramic enterprises is established, focusing on the whole life cycle of ceramic product and including four-story structure, such as the goal layer, energy conservation strategy layer, the life cycle layer and support layer, then focus on the analysis of the goal layer, energy conservation strategy layer, the life cycle layer and support layer respectively. For providing a method for decision analysis on the implementation of low-carbon manufacturing system of ceramic enterprises, a decision-making framework model of low-carbon manufacturing system of ceramic enterprises is established with the target of carbon emissions, time, quality and cost.
Secondly, based on the proposed low-carbon manufacturing system model of ceramic enterprises, the carbon emissions characteristics of ceramic product life cycle and the assessment techniques for carbon footprint are studied. Recalling the concept of carbon footprint and the basic theory of carbon footprint methods and life cycle assessment evaluation methods, and calculating the carbon emission factors of primary energy and secondary energy used in China and common materials of ceramic production, based on the theory of life cycle. The material balance model and energy balance model of ceramic enterprises are established for the quantifying the material and energy consumption of ceramic enterprises. Based on the carbon emissions factors of material and energy and the balance models of material and energy consumption, a new calculation method of carbon footprint of ceramic products is proposed, then, used to the analysis of carbon footprint of ceramic products.
Thirdly, for the characteristics that ceramic enterprises are the typical process-based industries and the modeling requirement of low-carbon manufacturing of ceramic enterprises, and according to the basic theory of fuzzy Petri nets, seizing the continuity of its running state and the effects of its discrete state on continuous process, the fuzzy Petri nets is applied to the modeling of low-carbon manufacturing process of ceramic enterprises successfully. This paper introduces the basic principles of Petri nets and gives the formal definition and rule description. According to the characteristics of ceramic production process, the fuzzy Petri nets framework model of production of enterprises and associated nested sub-models are established. The production process, resource allocation, waste heat recycling can be integrated by this model. For the foundation of the implementation of low-carbon manufacturing in enterprises, illustrating the application of this model with an example, the typical ceramic firing system, simulating the dynamic behavior of energy consumption of ceramic enterprises and highlighting the value of the model.
Finally, the low-carbon manufacturing system of ceramic enterprises and key technology are preliminarily applied in a ceramic company in Jiangxi, achieving good results and providing guidance and reference to the implementation of low-carbon manufacturing in ceramic enterprises.
引文
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