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1、 LBNL-50939-Revision Energy Efficiency Improvement and Cost Saving Opportunities for the Vehicle Assembly Industry An ENERGY STAR Guide for Energy and Plant Managers Christina Galitsky and Ernst Worrell Environmental Energy Technologies Division Sponsored by the U.S.Environmental Protection Agency M
2、arch 2008 ERNEST ORLANDO LAWRENCE BERKELEY NATIONAL LABORATORY Disclaimer This document was prepared as an account of work sponsored by the United States Government.While this document is believed to contain correct information,neither the United States Government nor any agency thereof,nor The Rege
3、nts of the University of California,nor any of their employees,makes any warranty,express or implied,or assumes any legal responsibility for the accuracy,completeness,or usefulness of any information,apparatus,product,or process disclosed,or represents that its use would not infringe privately owned
4、 rights.Reference herein to any specific commercial product,process,or service by its trade name,trademark,manufacturer,or otherwise,does not necessarily constitute or imply its endorsement,recommendation,or favoring by the United States Government or any agency thereof,or The Regents of the Univers
5、ity of California.The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof,or The Regents of the University of California.Ernest Orlando Lawrence Berkeley National Laboratory is an equal opportunity employer.i
6、Energy Efficiency Improvement and Cost Saving Opportunities for the Vehicle Assembly Industry An ENERGY STAR Guide for Energy and Plant Managers Christina Galitsky and Ernst Worrell Energy Analysis Department Environmental Energy Technologies Division Ernest Orlando Lawrence Berkeley National Labora
7、tory University of California Berkeley,CA 94720 March 2008 This work was funded by U.S.Environmental Protection Agencys Climate Protection Partnerships Division as part of ENERGY STAR.ENERGY STAR is a government-backed program that helps businesses protect the environment through superior energy eff
8、iciency.The work was supported by the U.S.Environmental Protection Agency through the U.S.Department of Energy Contract No.DE-AC02-05CH11231.ii iii Energy Efficiency Improvement and Cost Saving Opportunities for the Vehicle Assembly Industry Christina Galitsky and Ernst Worrell Energy Analysis Depar
9、tment Environmental Energy Technologies Division Ernest Orlando Lawrence Berkeley National Laboratory March 2008 ABSTRACT The motor vehicle industry in the U.S.spends about$3.6 billion on energy annually.In this report,we focus on auto assembly plants.In the U.S.,over 70 assembly plants currently pr
10、oduce 13 million cars and trucks each year.In assembly plants,energy expenditures is a relatively small cost factor in the total production process.Still,as manufacturers face an increasingly competitive environment,energy efficiency improvements can provide a means to reduce costs without negativel
11、y affecting the yield or the quality of the product.In addition,reducing energy costs reduces the unpredictability associated with variable energy prices in todays marketplace,which could negatively affect predictable earnings,an important element for publicly-traded companies such as those in the m
12、otor vehicle industry.In this report,we first present a summary of the motor vehicle assembly process and energy use.This is followed by a discussion of energy efficiency opportunities available for assembly plants.Where available,we provide specific primary energy savings for each energy efficiency
13、 measure based on case studies,as well as references to technical literature.If available,we have listed costs and typical payback periods.We include experiences of assembly plants worldwide with energy efficiency measures reviewed in the report.Our findings suggest that although most motor vehicle
14、companies in the U.S.have energy management teams or programs,there are still opportunities available at individual plants to reduce energy consumption cost effectively.Further research on the economics of the measures for individual assembly plants,as part of an energy management program,is needed
15、to assess the potential impact of selected technologies at these plants.iv Table of Contents 1.Introduction.1 2.The Motor Vehicle Industry.2 3.Vehicle Manufacturing Processes.3 4.Energy Use in Vehicle Assembly Plants.6 5.Energy Efficiency Opportunities.9 5.1.General Utilities.11 5.2.Motors Systems.1
16、8 5.3.Compressed Air Systems.22 5.4.Heat and Steam Distribution.30 5.5.Lighting.34 5.6.Heating,Ventilation and Air Conditioning(HVAC).38 5.7.Materials Handling and Tools.40 5.8.Painting Systems.40 5.9.Body Weld.47 5.10.Stamping.49 5.11.Miscellaneous.49 6.Summary and Conclusions.50 7.Acknowledgements
17、.52 8.References.53 Appendix A.Vehicle Assembly Plants in the United States(2000).64 Appendix B:Basic Energy Efficiency Actions for Plant Personnel.68 Appendix C:Guidelines for Energy Management Assessment Matrix.69 Appendix D:Check List for Organizing Energy Teams.73 Appendix E:Support Programs for
18、 Industrial Energy Efficiency Improvement.75 1 1.Introduction As U.S.manufacturers face an increasingly competitive environment,they seek out opportunities to reduce production costs without negatively affecting the yield or the quality of the product.Uncertain energy prices in todays marketplace ne
19、gatively affect predictable earnings.This is a concern,particularly for publicly traded companies in the motor vehicle industry.Successful,cost-effective investment into energy efficiency technologies and practices meets the challenge of maintaining the output of high quality product with reduced pr
20、oduction costs.This is especially important,as energy-efficient technologies often include“additional”benefits,increasing the productivity of the company further.Finally,energy efficiency is an important component of a companys environmental strategy.End-of-pipe solutions are often expensive and ine
21、fficient while energy efficiency can often be the cheapest opportunity to reduce pollutant emissions.In short,energy efficiency investment is sound business strategy in todays manufacturing environment.Voluntary government programs aim to assist industry to improve competitiveness through increased
22、energy efficiency and reduced environmental impact.ENERGY STAR,a voluntary program operated by the U.S.Environmental Protection Agency in coordination with the U.S.Department of Energy,stresses the need for strong and strategic corporate energy management programs.ENERGY STAR provides energy managem
23、ent tools and strategies for successful programs.The current paper reports on research conducted to support ENERGY STAR and its work with the vehicle assembly industry.This research provides information on potential energy efficiency opportunities for vehicle assembly plants.ENERGY STAR can be conta
24、cted through www.energystar.gov for additional energy management tools that facilitate stronger corporate energy management practices in U.S.industry.In this report,we assess the energy efficiency opportunities for vehicle assembly plants.Vehicle manufacture in the United States is one of the most i
25、mportant industries,producing 12-13 million cars and light trucks annually and generating almost$350 billion in output(Fulton et al.,2001).The industry(15 companies)operates 76 assembly plants(as of 2001)around the country,and a multitude of other plants manufacture car parts.In this report,we focus
26、 on the vehicle assembly plants,although a small number of these plants also manufacture parts onsite(e.g.engines,or vehicle body parts in stamping facilities).In the U.S.,the vehicle assembly industry spent$3.6 billion on energy in 1999(DOC,2000).We first describe the trends,structure and productio
27、n of the industry in the U.S.We then describe the main production processes.Following,we summarize the energy use in vehicle assembly plants and its main end uses.Finally,we discuss energy efficiency opportunities in vehicle assembly plants.We focus on measures and technologies that have successfull
28、y been demonstrated in individual plants in the U.S.or abroad,but that can still be implemented in other plants.Although new technologies are developed continuously(see e.g.Martin et al.,2000),we focus on practices that are proven and currently commercially available.2 2.The Motor Vehicle Industry T
29、he U.S.motor vehicle industry is the largest industry in the U.S.,producing more output(in dollars)than any other single U.S.industry(Fulton et al.,2001).Most of the sector of the industry that we are consideringvehicle assemblyis located in the Midwest,particularly in Michigan and Ohio.Detroit hous
30、es the headquarters of the“Big Three”automobile companies,General Motors Corporation(GM),Ford Motor Company and Daimler Chrysler Corporation.Table 1 lists the number of motor vehicle assembly plants in the U.S.for each state that has at least one plant for the year 2000(which includes automobiles,sp
31、ort utility vehicles(SUVs),light trucks,as well as buses and heavy-duty trucks).In 2000,the U.S.had 76 motor vehicle assembly plants.Appendix A lists each of these plants along with their capacity,product and operations at the plant.The industry as a whole directly employs over 621,000 workers.Table
32、 1.Location of U.S.vehicle assembly plants in 2000 State#Plants State#Plants MI 18 WA 2 OH 9 AL 1 KY 5 AR 1 MO 5 CA 1 NC 4 KS 1 IL 3 LA 1 IN 3 MD 1 DE 2 MN 1 GA 2 ND 1 NJ 2 OR 1 NY 2 PA 1 OK 2 TN 1 SC 2 VA 1 TX 2 WI 1 Total U.S.motor vehicle assembly plants=76 Globally,the U.S.motor vehicle industry
33、 is the largest in the world.In 1999,17 million vehicles were sold in the U.S.,over three times that of Japan,the next largest market(Fulton et al.2001).Thirteen million total motor vehicles were produced in the U.S.in 1999,30%more than Japan(Fulton et al.2001).Production data from 1978 to 1999 for
34、the U.S.are shown in Figure 1.In the automobile or light vehicle sector(cars,SUVs and light trucks),U.S.manufacturers can now compete with Japanese in product development on an international level,since the average time to market for U.S.automakers has decreased in the last few decades bringing it c
35、loser to those of Japanese producers(Fine et al.,1996).Within the U.S.,foreign automakers have expanded production;Japanese assemblers increased production from 2 to 3 million cars and light trucks per year from between 1991and 1996(Fine et al.,1996).Current domestic production in the automobile sec
36、tor is shifting from mostly cars to more light vehicles(trucks,minivans and SUVs).Figure 2 shows U.S.light vehicle production from 1990-1999.Light truck production doubled during this time.Several factors caused this shift,including their relatively low costs of production,little competition from fo
37、reign markets,and increasing demand,which drives up their prices.In 2001,production of light trucks grew to 56%of U.S.production(Fulton et al.2001).3 Figure 1.Total U.S.Vehicle Production from 1978 to 1999.Source:1990-1997:AAMA Economic Indicators,1998;1998-1999:Automotive News,2000.Figure 2.U.S.Lig
38、ht Vehicle Production from 1990-1999.6077543956645981661463516083592755565632346631763808460853225306544858586013702801,5003,0004,5006,0007,5009,00010,50012,00013,50015,00016,5001990199119921993199419951996199719981999Production(millions of vehicles)carslight trucks Source:1990-1997:AAMA Economic In
39、dicators,Q1 1998,page 5,Table 1 1998-1999:Automotive News,January 10,2000,page 58 In addition to trends towards light trucks(which include minivans and SUVs),consumer preferences are tending towards safety and amenities,like airbags and CD players.In the last two decades,average car prices increased
40、 faster than average U.S.incomes.This may shift consumers buying habits more towards used cars or keeping cars longer and away from buying new cars(Fine et al.,1996).3.Vehicle Manufacturing Processes 11.487.96.99.210.911.611.310.911.210.89.78.89.710.811.911.81211.912.21312.80246810121419781980198219
41、841986198819901992199419961998Production(Millions of Vehicles)4 Because many of the energy efficiency measures discussed in this report focus on the light vehicle sector,this section provides a description of this process.Automobile manufacturing basically consists of four steps:parts manufacture,ve
42、hicle body production,chassis production and assembly.Although we focus on vehicle assembly plants,some of the plants(See Appendix A)have other manufacturing facilities on-site(e.g.stamping).Therefore,we discuss the whole production process in this section,while providing more detail on the assembly
43、 process.Engine and Parts Manufacture The vehicle industry produces many parts itself(e.g.by subsidiaries),while other parts are purchased.Engines are cast from aluminum or iron,and further processed in engine plants.Metal casting is an energy-intensive production process.The U.S.Department of Energ
44、y has a special research effort focusing on the metal casting industry through its Metal Casting Industry of the Future Program,while the U.S.Environmental Protection Agency is helping to reduce the environmental impact of the process(e.g.recycling of casting sand)through its Industry Sector Perform
45、ance Program for Metal Finishing(DOE,2003a;EPA,2003a).Engine parts must be assembled to produce the finished engine.Other major cast parts are axles and transmissions.Vehicle Body Production Automotive and other vehicle bodies are generally formed out of sheet steel,although there is a trend toward
46、more plastic and aluminum parts in vehicle bodies.Different steel alloys are used because of their general availability,low cost and good workability.For certain applications,however,other materials,such as aluminum,fiberglass and reinforced plastic are used because of their special properties.For e
47、xample,Saturn(GM)uses plastic in doors and other vehicle body parts,while most manufacturers use plastic in bumpers.Tooling for plastic components generally costs less and requires less time to develop than that for steel components and therefore may be changed by designers at a lower cost,making it
48、 an attractive material for vehicle makers,despite its higher cost per pound.The relative low weight also contributes to higher fuel efficiency in cars.Chassis The chassis of the vehicle is the main structure of the vehicle.In most designs,a pressed-steel frame forms a skeleton on which the engine,w
49、heels,axle assemblies,transmission,steering mechanism,brakes,and suspension members are mounted.In modern small car designs,there has been a trend toward combining the chassis frame and the body into a single structural element.In this arrangement,the steel body shell is reinforced with braces that
50、make it rigid enough to resist the forces that are applied to it.Separate frames are used for other cars to achieve better noise-isolation characteristics.Painting To protect vehicle bodies from corrosion,special priming and painting processes are used.Bodies are first dipped in cleaning baths to re