Method for calculating process-level energy consumption and carbon emission of steam energy consumption in railway vehicle manufacturing process

Abstract

The invention relates to a method for calculating process-level energy consumption and carbon emission of steam energy consumption in a railway vehicle manufacturing process. The method comprises the following steps of: establishing an energy consumption node data structure and encoding the energy consumption node data structure; all parameters of the influence period energy consumption are called; a standardized calculation formula is established, the energy consumption value of each energy consumption process resource node is obtained, and a data set of the whole manufacturing stage is formed; summing and summarizing to obtain the sum of energy consumption of the single energy consumption type in each manufacturing stage in the product manufacturing process; the total energy consumption of each single energy consumption type in the unit product manufacturing process is obtained; and converting the energy consumption data of each layer of a unit product into corresponding carbon emission. According to the method, the parameterized standard library covering all steam energy use process resources is established, single data source management of process level energy consumption process resources is achieved, and the method can be used for supporting development and application of a process level carbon emission accounting information system.

Description

Technical Field

[0001] The present invention relates to the technical field of rail vehicle manufacturing, and particularly relates to a method for calculating the energy consumption and carbon emission at the process level of the steam energy usage amount during the manufacturing process of rail vehicles. Background Art

[0002] Steam consumption refers to the consumption of steam during production. Steam is mainly used in the rail vehicle manufacturing workshop to provide heating for spaces with special temperature control requirements, etc.

[0003] In the prior art, the calculation of the carbon emission value of steam-consuming process resources is mainly the empirical statistical method. The specific calculation method is as follows:

[0004] The manufacturing process of a product is split into processes, the energy consumption is directly counted according to the processes, and then the carbon emission of the process is calculated. By summarizing, the total carbon emission of various energies used in the manufacturing process of producing one product is obtained.

[0005] For the data in the following table, when calculating the carbon emission value of the steam energy usage amount based on the empirical statistical method, only the energy consumption needs to be directly counted according to the processes, and then the carbon emission of the process is calculated. By summarizing, the total carbon emission W of the steam energy usage amount in the manufacturing process of producing one product is obtained.

[0006]

[0007] For steam-consuming process resources, the total carbon emission W is the total steam energy usage amount, and it satisfies:

[0008]

[0009] where i is the process sequence, W i is the steam amount allocated to the process, and m represents the process number.

[0010] The end statistic of this empirical statistical method is the process, and it does not correspond to specific energy-consuming hardware. Therefore, basically, each product independently accounts for its own data, and no general calculation model and standard process resources are formed. Summary of the Invention

[0011] The present invention aims to solve the technical problems in the prior art and provides a method for calculating the energy consumption and carbon emission at the process level of the steam energy usage amount during the manufacturing process of rail vehicles.

[0012] To solve the above technical problems, the technical solution of the present invention is as follows:

[0013] A method for calculating the energy consumption and carbon emission at the process level of the steam energy usage amount during the manufacturing process of rail vehicles includes the following steps:

[0014] Step 1: Taking the energy-consuming process resources as the end nodes, establish an energy consumption node data structure and encode it; in the order of the time axis of the operation execution within the manufacturing stage, establish energy-consuming nodes with the energy-consuming process resources as the objects according to the operations or the sub-operations within the operations, encode the process resource nodes according to the operation levels, and use multi-dimensional arrays for encoding according to the level situation.

[0015] Step 2: For the energy-consuming process resource nodes, call all the parameters that affect their energy consumption.

[0016] Step 3: Establish a standardized calculation formula, and through the coupling between the parameters, obtain the energy consumption values of each energy-consuming process resource node and form a data set for the entire manufacturing stage.

[0017] Step 4: Obtain the total energy consumption of a single energy-consuming type in each manufacturing stage during the product manufacturing process by summing up the energy consumption data at the operation level.

[0018] Step 5: Obtain the total energy consumption of each single energy-consuming type in the manufacturing process of a unit product by summarizing the energy consumption of a single energy-consuming type in all manufacturing stages of manufacturing a unit product.

[0019] Step 6: Adopt the emission factor method to convert the energy consumption at each level in the product manufacturing process into the corresponding carbon emissions.

[0020] In the above technical solution, in Step 2, all the parameters that affect the energy consumption during the influencing period include: all the technical parameters of the hardware individuals of the energy-consuming process resources within the operation, the operation working duration parameter, and the energy-consuming resource starting rate parameter.

[0021] In the above technical solution, all the technical parameters of the hardware individuals of the energy-consuming process resources within the operation in Step 2 include: the rated power.

[0022] In the above technical solution, Step 2 is specifically:

[0023] The theoretical steam consumption of the energy-consuming node corresponding to each energy-consuming process resource satisfies:

[0024] W ij =[W a ×P+(T i ×Q ij -1)×W b ×P]×X ij

[0025] Where, i is the operation sequence, j is the serial number of the energy-consuming process resource used within the operation, T i is the working cycle duration of each step of the operation, Q ij is the starting rate of the energy-consuming process resource within each operation, X ij is the usage quantity of the energy-consuming process resource within the operation, and W aIt is the steam consumption per unit volume of the space in the first hour during the use of energy-consuming process resources, W b It is the steam consumption per unit volume of the space per hour after the first hour during the use of energy-consuming process resources. P is the volume of the temperature control place, W ij It is the steam consumption during the use of energy-consuming process resources.

[0026] The present invention has the following beneficial effects:

[0027] The method for calculating the process-level energy consumption and carbon emissions of steam energy usage in the manufacturing process of rail vehicles of the present invention realizes the single data source management of energy-consuming process resources at the process level by establishing a parameterized standard library covering all steam energy-using process resources, and can be used to support the development and application of the process-level carbon emission accounting information system.

[0028] Applying the method for calculating the process-level energy consumption and carbon emissions of steam energy usage in the manufacturing process of rail vehicles of the present invention, each energy-consuming process resource used in the product manufacturing process is used as an energy-consuming node. By expressing the energy-consuming process of the energy-consuming process resource with a parameterized model and binding and calculating the energy-consuming process with the specific functional parameters of the energy-consuming hardware, it has very strict logical self-consistency. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The present invention will be further described in detail below in conjunction with the drawings and specific embodiments.

[0030] Figure 1 It is a schematic diagram of the relationship among the manufacturing stage, process, and energy-consuming process resources in the product manufacturing process.

[0031] Figure 2 It is a schematic flow chart of the steps of the method for calculating the process-level energy consumption and carbon emissions of steam energy usage in the manufacturing process of rail vehicles of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0032] The present invention will be described in detail below in conjunction with the drawings.

[0033] The method for calculating the process-level energy consumption and carbon emissions of steam energy usage in the manufacturing process of rail vehicles of the present invention, as Figure 2 shown, includes the following steps:

[0034] Step 1: Taking the energy-consuming process resource as the end node, establish an energy consumption node data structure and encode it. Taking the time axis of the process execution within the manufacturing stage as the order, establish energy-consuming nodes with the energy-consuming process resource as the object according to the process or the sub-processes within the process, and encode the process resource nodes according to the process level. The encoding uses a multi-dimensional array according to the hierarchical situation.

[0035] Step 2: For the energy-consuming process resource nodes, call all the parameters that affect their energy consumption, including but not limited to all technical parameters (including rated power) of the hardware individuals of the energy-consuming process resources within the process, the working duration parameters of the process (including the work steps within the process), the starting rate parameters of the energy-consuming resources, etc.

[0036] Step 3: Establish a standardized calculation formula. Through the coupling of various parameters, obtain the energy consumption values of each energy-consuming process resource node, and form a dataset for the entire manufacturing stage.

[0037] Step 4: Obtain the total energy consumption of a single energy type in each manufacturing stage during the product manufacturing process by summing up the energy consumption data at the process level.

[0038] Step 5: Obtain the total energy consumption of each single energy type in the manufacturing process of a unit product by summing up the energy consumption of a single energy type in all manufacturing stages of manufacturing a unit product.

[0039] Step 6: Adopt the emission factor method to convert the energy consumption at each level in the product manufacturing process into the corresponding carbon emissions.

[0040] The following takes the calculation of the steam energy consumption in some processes of the car body painting process stage of a certain rail vehicle product as an example to elaborate in detail on the calculation method of the steam energy consumption and carbon emissions at the process level in the rail vehicle manufacturing process of the present invention.

[0041] The theoretical steam consumption of the energy-consuming node corresponding to each energy-consuming process resource satisfies:

[0042] W ij =[W a ×P+(T i ×Q ij -1)×W b ×P]×X ij (Formula 1)

[0043] Among them, i is the process sequence, j is the serial number of the energy-consuming process resource used within the process, T i is the working cycle duration of each step of the process, Q ij is the starting rate of the energy-consuming process resource within each process, X ij is the usage quantity of the energy-consuming process resource within the process, W a is the steam consumption per unit volume of space in the first hour during the use of the energy-consuming process resource, W b is the steam consumption per unit volume of space per hour after the first hour during the use of the energy-consuming process resource, P is the volume of the temperature control site, and W ij is the steam consumption during the use of the energy-consuming process resource.

[0044] Specifically, W aIt refers to the amount of steam required per unit volume of the closed space with a fixed volume to heat the space temperature from room temperature of 20 °C to the process-required temperature (default is 60 °C) within 1 hour; W b It refers to the amount of steam required per unit volume per hour when the space temperature reaches the process-required temperature and continues to maintain this temperature. W a and W b are both performance parameters of energy-consuming process resources.

[0045] During the vehicle body painting manufacturing stage, steam is used to provide energy for drying and temperature adjustment of products in the closed space of the process. The steam consumption is related to the volume of the closed space and the heating and heat preservation settings. Specific parameters need to be determined through factory tests or on-site tests at the usage location for the corresponding energy-consuming process resources. The default process temperature of this invention is 60 °C. When the process temperature is higher or lower than 60 °C, the energy consumption ratio relative to 60 °C should be measured through tests, and the corresponding process temperature should be calculated using the proportionality coefficient.

[0046] As Figure 1 shown below, the calculation method of steam energy consumption and carbon emissions at the process level during the manufacturing process of rail vehicles of this invention will be described in detail with specific examples.

[0047] Table 1 Functional Parameter Table of Steam-consuming Process Resources

[0048]

[0049] The parameters adopted in Table 1 as an example are as follows: P = 29 m × 4.4 m × 5.5 m = 701.8 cubic meters,

[0050] W a = 0.000712454 tons, W b = 0.000213736 tons. Each ton of steam produced by the natural gas boiler consumes 70 cubic meters of natural gas (adjustable according to the boiler situation), and the natural gas carbon emission factor is 2.0 kg of carbon dioxide per standard cubic meter.

[0051] Table 2 Energy Consumption Calculation Table of Steam-consuming Process Resources

[0052]

[0053]

[0054] In Table 2, the "Process Sequence" in the title column is the serial number of the process sequence. The parameter variable in the formula is "i", which is a one-dimensional serial number in this embodiment. When other processes require further subdivision of steps, or there are multiple sub-process chains, or there are parallel processes, they should be further subdivided within the sequence label, and multi-dimensional array numbers can be used.

[0055] In Table 2, the "Resource Serial Number" in the title bar is the serial number of the energy-consuming process resources within the process, and "j" is used as its parameter variable in the formula.

[0056] In Table 2, the "Working Cycle" is the working duration from the start to the end of a certain process, in hours, and "T" i is used as its parameter variable in the formula.

[0057] In Table 2, the "Working Cycle Operation Rate" indicates the proportion of the working duration of a certain energy-consuming process resource within a certain process during the working cycle of this process, expressed as a percentage. If there are multiple of the same energy-consuming process resources, the percentage is given according to the average single usage duration proportion or is represented separately for different process resources. "Q" ij is used as its parameter variable in the formula.

[0058] In Table 2, the "Energy-consuming Process Resource" refers to the steam energy-consuming process resources applied to the process, which is a sub-category of the energy-consuming process resources.

[0059] In Table 2, the "Quantity" refers to the number of the same energy-consuming process resources used within a certain process, and "X" ij is used as its parameter variable in the formula.

[0060] In Table 2, the "Energy Consumption Quantity" is the steam quantity allocated to the process, and "W" ij is used as its parameter variable in the formula, with the unit of ton.

[0061] According to the data in Table 1 and Table 2, the calculation process of the steam energy usage during the manufacturing process of rail vehicles is as follows:

[0062] The first step: Taking the energy-consuming process resources as the end nodes, establish an energy consumption node data structure and encode it to obtain all the data in Table 1 and the data of the first 8 columns (from left to right) in Table 2;

[0063] The second step: Call all the data in Table 1 and the data of the first 8 columns (from left to right) in Table 2;

[0064] The third step: According to "Formula 1", all the data of the 9th column in Table 2, that is, the steam quantity W ij allocated to the process, can be obtained.

[0065] W 51 = [0.000712454 * 701.8 + (3 * 90% - 1) * 0.000213736 * 701.8] * 2 = 1.51 tons

[0066] W 61 =...... The algorithm is the same as above

[0067] The fourth step: Through summarization, obtain the total steam usage quantity W during the process of car body painting manufacturing stage.

[0068] W = 1.51 + 1.3 + 1.24 +...... = 33.39 tons

[0069] Step 5: Convert the steam volume to the natural gas consumption of the natural gas boiler for producing steam.

[0070] 33.39 * 70 = 2337.3 cubic meters

[0071] Step 6: Use the emission factor method to convert it to the total carbon emissions of the steam consumed in the vehicle body painting manufacturing stage.

[0072] 2337.3 * 2.0 = 4674.6 kg of carbon dioxide

[0073] The calculation method for the process-level energy consumption and carbon emissions of the steam energy used in the manufacturing process of the rail vehicle of the present invention realizes the single data source management of the energy-consuming process resources at the process level by establishing a parameterized standard library covering all the process resources of the steam energy used, and can be used to support the development and application of the process-level carbon emission accounting information system.

[0074] Applying the calculation method for the process-level energy consumption and carbon emissions of the steam energy used in the manufacturing process of the rail vehicle of the present invention, each energy-consuming process resource used in the product manufacturing process is used as an energy-consuming node. By expressing the energy-consuming process of the energy-consuming process resource in a parameterized model and binding and calculating the energy-consuming process with the specific functional parameters of the energy-consuming hardware, it has very strict logical self-consistency.

[0075] Obviously, the above embodiments are only examples for clear illustration and not limitations on the implementation manners. For those of ordinary skill in the art, other different forms of changes or variations can be made based on the above description, including but not limited to the calculation of energy consumption and carbon emissions of other energy types. It is not necessary and impossible to list all the implementation manners here. And the obvious changes or variations derived therefrom are still within the protection scope of the present invention.

Claims

1. A method for calculating the energy consumption and carbon emissions at the process level of the steam energy usage in the manufacturing process of rail vehicles, characterized in that, It includes the following steps: Step 1: Taking the energy-consuming process resources as the end nodes, establish an energy consumption node data structure and encode it; Taking the time axis of the process execution within the manufacturing stage as the order, establish energy-consuming nodes with energy-consuming process resources as the objects according to the processes or the sub-steps within the processes, encode the process resource nodes according to the process hierarchy, and use multi-dimensional arrays for encoding according to the hierarchy situation; Step 2: For the energy-consuming process resource nodes, call all the parameters that affect their energy consumption; Step 3: Establish a standardized calculation formula, and through the coupling between the parameters, obtain the energy consumption values of each energy-consuming process resource node, and form a data set for the entire manufacturing stage; Step 4: Obtain the total energy consumption of a single energy consumption type in each manufacturing stage during the product manufacturing process by summing up the energy consumption data at the process level; Step 5: Obtain the total energy consumption of each single energy consumption type in the unit product manufacturing process by summarizing the energy consumption of a single energy consumption type in all manufacturing stages of manufacturing a unit product; Step 6: Adopt the emission factor method to convert the energy consumption at each level in the product manufacturing process into the corresponding carbon emissions.

2. The calculation method of steam energy consumption, process-level energy consumption and carbon emissions in the manufacturing process of rail vehicles according to claim 1, wherein In Step 2, all the parameters that affect the energy consumption during the period include: all the technical parameters of the hardware individuals of the energy-consuming process resources within the process, the process working duration parameters, and the energy-consuming resource operation rate parameters.

3. The method for calculating the energy consumption and carbon emissions at the process level of the steam energy consumption during the manufacturing process of rail vehicles according to claim 2, wherein All the technical parameters of the hardware individuals of the energy-consuming process resources within the process in Step 2 include: the rated power.

4. The method for calculating the energy consumption and carbon emissions at the process level of the steam energy usage amount in the manufacturing process of rail vehicles according to claim 1, wherein, Step 3 is specifically as follows: The theoretical steam consumption of the energy-consuming node corresponding to each energy-consuming process resource satisfies: W ij = [W a × P + (T i × Q ij - 1) × W b × P] × X ij Among them, i is the process sequence number, j is the serial number of the energy-consuming process resources used within the process, T i is the working cycle duration of each process step, Q ij is the starting rate of the energy-consuming process resources within each process, X ij is the quantity of the energy-consuming process resources used within the process, W a is the steam consumption per unit volume of space in the first hour during the use of the energy-consuming process resources, W b is the steam consumption per unit volume of space per hour after the first hour during the use of the energy-consuming process resources, P is the volume of the temperature control site, W ij is the steam consumption during the use of the energy-consuming process resources.

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