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Decarbonising steelmaking
This article, one of many NZ Manufacturer will be sharing on the subject, comes as a result of conversations with companies in the steel industry who require information on decarbonising steel and steelmaking. Seventy five percent of steel is made from high-emissions plants Nearly three-quarters of crude steel today is made from iron ore in blast furnace–basic oxygen furnace (BF-BOF) plants. These plants release carbon when coking coal is burned and used as a reducing agent. One key decarbonisation action could be to replace blast furnaces with electric arc furnaces fed by scrap and/or H2-DRI; powering EAFs with 100 percent carbon-neutral electricity would eliminate energy-related emissions. Moving to low-emissions production would require $4.4 trillion spending over the next 30 years, with the top end spend coming between 2030 and 2040. In this scenario, three-quarters of investment will likely be on new hydrogen-powered DRI-EAF plants, and the rest to equip existing BF-BOF plants with CCS. Thirty percent increase in unit production costs for steel Costs for steel in the net-zero scenario could increase because of up-front capital spending and higher operating costs associated with CCS and hydrogen-based DRI-EAF production. Market opportunities The shift toward net-zero steel production would likely depend on a collaborative effort among regulators, governments, and industry stakeholders to change the economics of production, facilitate access to required capital, and stimulate demand. First movers that manage the transition risks well stand to gain the most. Sixty five percent of steel will come from plants with electric arc furnaces in 2050 and there will be a ten percent increase in global demand for steel compared with today. Getting all the way to net-zero steel Recent developments in regulations, along with commitment among some governments to reduce CO₂ emissions, have led many steelmakers to set high decarbonisation goals in coming years. While […]
Where to for sustainability in an economic downturn?
-Dr. Barbara Nebel, CEO, thinkstep-anz Is sustainability a ‘fair weather friend’ in your manufacturing business? Do you see it as something to cut back when recession calls? If so, you’re missing a business opportunity. Building a more environmentally and socially sustainable business can make your business more efficient and resilient and help you weather the storms ahead. The New Zealand government is forecasting a recession in 2023. This is difficult news for manufacturers already challenged by creaky supply chains and a tight market for skills. Make the most of the many opportunities sustainability offers. Business benefit: reduce your costs Understand your environmental impacts – and reduce them Everything that goes into making your product has an environmental footprint – and a dollar cost. Start by understanding your footprint. A Product Carbon Footprint study measures the carbon your products generate. A Life Cycle Assessment (LCA) considers other impacts too, including the water you use and the waste you generate. Food manufacturer Comvita’s LCA NZ Manufacturer October 2022 by Media Hawkes Bay Limited – Issuu will help the business understand the environmental impacts of its ‘honey in a pot’, from growing the mānuka forests the bees feed on to disposing of the honey’s empty packaging. Armed with information about your environmental impacts, look at whether you can cut some costs. Can you reduce the amount of energy you use? Use raw materials more efficiently? Cut the waste you generate and the costs of disposing of it? The beauty of LCA is that it shows trade-offs. It will help you understand how tweaking one aspect of your product (e.g. the energy you use) affects other aspects (e.g the waste you generate). Buy responsibly Purchasing goods and services produced in environmentally and socially responsible ways can save you money. For example, buying from local […]
SailGP Technologies delivers high performance sustainable innovations
Andrea Rosenbaum -SailGP Technologies Boat Builder and Tech Team member. SailGP Technologies is rooted in decades of experience at the forefront of cutting-edge sail racing. Having rebranded from Core Builders Composites in 2022, SailGP Technologies launches to deliver high performance sustainable innovations from sea to space. At their world-class facility in Warkworth, New Zealand, the team integrates state-of-the-art technology to enhance production efficiencies and increase overall accuracies, while reducing lead times. The in-house quality assurance and nondestructive testing processes ensure consistent high quality results. SailGP Technologies CEO Sir Russell Coutts and Managing Director Dave Ridley. SailGP Technologies produce composite prototypes and tooling and assists customers in developing efficient and cost-effective manufacturing systems. Expertise ranges from high end metal machining and fabrication, prepreg curing and tooling from Aluminium, Carbon Fibre and Graphite materials. The Warkworth facility houses six dedicated composite CNC machines, such as the MultiCam, 2D Eastman and the CMS Poseidon with a 5-axis CNC high speed gantry machine, and a working area of 18m x 6.2m x 3m and 6m x 6.2m x 3m. The Poseidon machine has been used extensively for large composite tooling, highly accurate appendage programmes, as well as architectural, industrial and film projects. The qualified technicians at SailGP Technologies are highly passionate with retained knowledge passed from one generation to the next through in-house training and apprenticeships. Coming from a strong heritage in the high performance marine industry, has seen the team lead in competitive composite racing yacht construction since 2001. This dedication to design innovation can more recently be seen in the development of the F50 boats used by the SailGP global racing championship, powering the world’s fastest growing, purpose-led, global racing league. “We are excited about the expansion and the opportunities that will come from delivering the same relentless innovation to customers across […]
Choose applications relevant to your needs
From NZ Manufacturer, October 2023 -Adam Sharman, Senior Partner, dsifer As organisations look to embrace the benefits of digitisation through automation, IoT and AI, a trend is emerging that embraces the growing availability, specificity and cost effectiveness of a plug-and-play approach to developing an IT and data architecture. Advances in functionality, connectivity and speed to deployment have resulted in the ability to pick and choose applications that are relevant to the specific requirements of the organisation’s industry, operations and environment at a time when the vast majority of IT professionals report significant time waste due to bloated, generic applications. Whilst this trend towards a plug-and-play system architecture has multiple benefits, it requires careful consideration of the underpinning data architecture to ensure that, not only are data privacy and sovereignty maintained but that the data generated by the plug-and-play ecosystem is collected and utilised as a performance and strategic asset. In our interactions with manufacturing businesses in New Zealand and the UK, we are seeing the importance of establishing an independent, centralised data architecture as an enterprise asset to support the plug-and-play IT architecture, receiving data feeds from the operational systems, and using a combination of these source datasets to create meaningful and actionable insights. There is still much debate on the relative benefits of physical centralisation (data lakehouse) versus a virtually centralised (data mesh). In our experience, both have their place depending on the organisation’s context. However, the key characteristic of the data architecture that supports a plug-and-play IT approach are that the data assets, architecture and governance are independent of the IT applications, data siloes are removed to support integrated enterprise insight and access points are decoupled to accelerate collaboration whilst maintaining data integrity. Organisations who have adopted this approach report multiple benefits, including: Enhanced Data Governance and […]
igus unveils world’s first urban bike made from recycled plastic
No maintenance, no corrosion- the igus:bike sets new standards in sustainable mobility With its expertise in plastics for movement, Treotham is making the concept and components available to all bicycle manufacturers on the new igus:bike platform. The first model should be available by the end of the year. The world is drowning in plastic waste. The huge piles in landfill sites are growing fast. Some of this plastic ends up in the ocean, enters the food chain, and becomes a danger to marine, animal and human life. Therefore it is most urgent to move away from the traditional linear economic model and migrate to a fully circular economy. To help this transformation, igus the motion plastics specialist has been developing and investing in ideas for recycling plastics for many years. The company recently presented a world first: The concept of a robust, durable urban bike made entirely of plastic, from frame to bearings to toothed belt. One special feature of this new bike is that the recycled version will be primarily made of reused plastics originally “single use”. “The plastic in rubbish dumps around the world is becoming a valuable resource,” explains Frank Blase, igus CEO. He first had the idea of a bicycle, now known as the “igus:bike”, on a beach while on holiday. In conversations with employees of a bicycle rental company on the beach, he found out about their major problems with beach bikes. These were continuously exposed to sand, wind and saltwater and sometimes only lasted three months before they had to be replaced. Maintenance and replacement are often expensive and time-consuming in this industry. “The igus:bike does not rust.” The igus:bike is easier to own than any other bike. Owners can leave the single-speed bike outdoors in all weather and clean it in seconds with […]
Southland businesses benefiting from investment in technology
Businesses from Southland to as far afield as Canterbury are benefiting from a new computer numerical control (CNC) laser cutter investment from Southland firm MPE Limited, the first of its kind in the region. MPE Managing Director, Chris Hughes, said offering this technological capability had been highly sought after given the current pressures on labour and the continued focus on increased productivity currently experienced by southern manufacturing industries. “We’re helping our customers where we can, by taking the manual work out of specific jobs that can sometimes take days or weeks to complete. The automated function of the laser saves time and money, leaving the staff to utilise their time and skills more efficiently to add real value elsewhere in our clients’ businesses,” he said. Not only is the new machinery the single largest investment MPE has seen in decades, it is also an investment for the general industry in the lower to mid-South Island, offering customers a new, intelligent automated option for their steel processing and engineering needs. Chris said there were several machines that cut flat plate and used similar technology, but no machines in Southland that could do this to various profiles of sections other than plate. The design software converts 3D files into a code format for the machine and then the computer’s numerical control process takes over and produces high precision parts at speed which are more efficient than traditional methods, thus saving time and resources. Not only does it cut steel sections, but it was also designed and manufactured to be able to cut through a range of different profile sections in various steel, stainless steel, aluminium, brass and other material types. Chris said that MPE had further integrated into their clients’ supply chain by performing this type of work which has allowed their […]
NanoLayr’s sustainability roadmap charts the way
Article from Dr.Barbara Nebel,CEO, thinkstep-anz www.thinkstep-anz.com Want to make your manufacturing business more environmentally and socially sustainable? When you’re a busy manufacturer, investing in a sustainability roadmap can be the difference between talking about sustainability and making it happen. In this article we explain what a sustainability roadmap is and why your business needs one. We also talk with Auckland-based functional textile manufacturer NanoLayr about the benefits it’s seeing from theirs. What is a sustainability roadmap? A sustainability roadmap charts the course your business plans to take to become more environmentally and socially sustainable. Think of it like a Google map. Plug in your destination (a more sustainable manufacturing business) and Google offers up a host of ideas to help you with your journey. Street names and directions? These are the high-level sustainability actions you need to take to reach your destination. In a manufacturing business they may include sourcing renewable materials or tackling waste in your packaging. Alternative routes? Think of these as your options and trade-offs. There are many ways to become more sustainable. You’ll need to assess different projects and prioritise them. Distances and different modes of transport? These are the resources you’ll need to commit and the people you’ll need to involve: team members with clear responsibilities, external stakeholders such as suppliers, and (probably) some budget. Journey times? They’re the high-level timelines you’ll work to. Map your sustainability actions into blocks of time. You may be able to complete some within six months to a year. Other activities will take longer. Assign them over the medium term (say one to two years) and longer term (say two years plus). Bring this ‘journey’ information together and you have your sustainability roadmap: a summary of your sustainability goals and the projects, resources and timetable that will help […]
Rise of the Machines – is technology really replacing humans?
– Catherine Lye, Head of Advanced Manufacturing and Export Communities, EMA As our Smart Factory Showcase continues building momentum in the Industry 4.0, manufacturing and technology space, it’s time to share some insights into what we’ll be covering during each session. Each Smart Factory Showcase covers several key areas of operation at Nautech Electronics. These include sales and planning, systems, connectivity, research and development, production, testing, facilities, smart business models and implementation strategies. Industry 4.0 and the showcase are all about highlighting how a range of digital technologies enhance manufacturing performance, output, monitoring and control, keeping businesses globally competitive. Today, we’ll consider the view that the adoption of new technologies could lead to the replacement of the human element required in manufacturing – or does it? Many of us have seen The Terminator film series where the artificially intelligent machines become self-aware and hostile with an aim to take over the world in a post-apocalyptic future. As Laurie Kubiak, CEO of Nautech Electronics assures us, people are always going to be necessary for the safe and successful operation of manufacturing machinery and technology. Adopting new technology is about making everyone’s lives easier, both for the company and its people. People are required for all parts of Nautech’s operations, particularly for forward-planning, scheduling, stock management, programming and much more. They cannot be replaced. Adopting Industry 4.0 and smart technologies actually has the potential to create more job opportunities, as people become vital in ensuring maximum machine efficiency, productivity, outputs and operation. Cobots (collaborative robots) are often used to take on certain repetitive tasks that humans could do, but they are able to maintain consistency and run for longer periods. They don’t need to work a standard shift or stop for breaks. Passing on these mundane tasks to cobots also has health […]
Harness the power of words to make your business more sustainable
-Barbara Nebel, thinkstep-anz This month’s sustainability tip: pick up your pen (physical or digital). Why? Because clear, engaging communication and reporting will make your manufacturing business more sustainable. Harnessing the power of words will help you define your sustainability strategy and share it with the people who matter to your business. Get your sustainability strategy down ‘on paper’ We love this quote from Pulitzer Prize winner David McCullough: ‘Writing is thinking. To write well is to think clearly. That’s why it’s so hard.’ We think he’s right. Getting your sustainability programme down ‘on paper’ will force you to consider how sustainability fits into your business strategy. What really matters to make sure your business ‘goes the distance’? How can you make it more sustainable? Who do you need to involve? What are the risks and opportunities? What targets will you set and how will you know if you meet them? If you haven’t already, get writing. Our tips: focus on what matters. (Strategy is about what you leave out as well as what you put in.) Keep your document short. Use ‘dinner-table language’: simple words, short sentences, personal language like ‘we and you’. Communicate your products’ environmental performance Tell your customers how you’re making your products more sustainable. Consider producing an Environmental Product Declaration (EPD) for a product. In our last article, we featured manufacturer Red Stag Wood Solutions’ EPD for sawn and planed timber products. An EPD tells the environmental story of a product over its life cycle in a clear, simple format that a wide audience can understand. It will help you translate complex environmental information about your product’s environmental footprint into simpler information that your wholesale and retail customers can trust to make decisions. Every EPD is based on data from a detailed environmental study called a […]