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1、Towards Net-Zero ElectronicsUnlocking the power of energy efficiency in manufacturing facilitiesReport/April 2025About RMIRMI is an independent nonprofit,founded in 1982 as Rocky Mountain Institute,that transforms global energy systems through market-driven solutions to align with a 1.5C future and

2、secure a clean,prosperous,zero-carbon future for all.We work in the worlds most critical geographies and engage businesses,policymakers,communities,and NGOs to identify and scale energy system interventions that will cut climate pollution at least 50 percent by 2030.RMI has offices in Basalt and Bou

3、lder,Colorado;New York City;Oakland,California;Washington,D.C.;Abuja,Nigeria;and Beijing,Peoples Republic of China.Authors and AcknowledgmentsAuthorsTing LiWei LiGuangxu WangMeng WangAuthors listed alphabetically.All authors from RMI unless otherwise noted.ContactsWei Li,wlirmi.orgGuangxu Wang,gwang

4、rmi.orgCopyrights and CitationWei Li,Guangxu Wang,and Meng Wang,Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilities,RMI,2025,https:/rmi.org/insight/towards-net-zero-electronics/.RMI values collaboration and aims to accelerate the energy transition throug

5、h sharing knowledge and insights.We therefore allow interested parties to reference,share,and cite our work through the Creative Commons CC BY-SA 4.0 license.https:/creativecommons.org/licenses/by-sa/4.0/.Images are from iS unless otherwise noted.rmi.org/4Towards Net-Zero Electronics:Unlocking the p

6、ower of energy efficiency in manufacturing facilitiesTable of Contents1.Why Supply Chain Energy Management Matters in the Electronics Manufacturing Industry.5Importance of supply chain energy efficiency in the electronics manufacturing industry.5Managing energy efficiency in final assembly,testing,a

7、nd packaging(FATP)facilities.72.Retrofitting Existing Facilities for Energy Efficiency.9Key considerations in an energy audit.10Systems investigation for optimal energy-saving potential.11Process air system.12HVAC system.15Production system.17Lighting and other facility appliances.19Project implemen

8、tation and acceptance.21Savings verification.223.Planning for Optimum Energy Efficiency in New Facilities.24Key principles for new FATP facilities with an integrated design approach.24Implementing integrated design:key considerations for energy efficiency in new FATP facilities.27Building and facili

9、ty layout.27System and equipment.28Control and monitoring.28Endnotes.31rmi.org/5Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilities1.Why Supply Chain Energy Management Matters in the Electronics Manufacturing IndustryThe electronics manufacturing industr

10、y is experiencing rapid growth,driven by the global shift toward digitization,automation,and technologies such as 5G,the Internet of Things,and artificial intelligence(AI).The global electronics market was valued at$1.275 trillion in 2023 and is growing at a rate of 7.5%,with the AsiaPacific region

11、and North America driving demand.1 In China,the electronics manufacturing industry was the top industry in terms of revenue from 2013 to 2023.Chinas supply-chain market reached RMB 37.72 trillion(US$5.2 trillion)in 2023,with about 41,200 electronics manufacturing companies.2The electronics industry

12、plays a critical role in the global energy transition and efforts to combat climate change;as demand for electronic products increases,so does the sectors environmental impact,particularly in terms of energy consumption and emissions.The electronics industry is estimated to be responsible for more t

13、han 4%of global greenhouse gas emissions.3 By driving innovation in energy technologies,the sector is helping reduce greenhouse gas emissions and moving toward a more sustainable,low-carbon economy.Energy efficiency is a key pillar in the global energy transition and the fight against climate change

14、 because it directly reduces energy demand,greenhouse gas emissions,and the need for fossil fuels.The International Energy Agency(IEA)calls energy efficiency the“first fuel”for achieving climate goals and says it can deliver more than 40%of the emissions reductions needed by 2040 in the IEAs Sustain

15、able Development Scenario.4 Improving energy efficiency in a wide range of manufacturing applications not only reduces energy consumption but also enhances the viability of renewable energy sources,increases energy security,and lowers energy costs.Research conducted by McKinsey&Company shows potenti

16、al energy savings of 25%to 30%in fabrication facilities with neither loss of quality nor worker-safety compromises and little new investment.5Importance of supply chain energy efficiency in the electronics manufacturing industrySupply chain carbon emissions management is critical in the electronics

17、manufacturing industry.Consumer electronics suppliers,including semiconductor manufacturers,display manufacturers,and final assemblers,account for over 77%of the electronics industrys total emissions(see Exhibit 1).This highlights the significant impact that upstream activities within the supply cha

18、in have on the overall carbon footprint.Effective management of energy use across these supply-chain stages is essential for the industry to progress toward net-zero emissions.This data underscores the necessity of addressing Scope 3 emissions,which include all indirect emissions that occur in the v

19、alue chain,from raw material extraction to the production of final goods.rmi.org/6Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesExhibit 1 Emissions split in Scopes 1,2,and 3 upstream for selected industries(CO2e,2019)Note:Top companies were selected

20、 based on the number of reported Scope 3 upstream categories and industry fit.FMCG means fast-moving consumer goods.CO2e means carbon dioxide equivalent.RMI Graphic.Source:Carbon Disclosure Project;Boston Consulting Group;Net-Zero Challenge:The Supply Chain Opportunity,World Economic Forum,2021Energ

21、y efficiency is a crucial lever for reducing emissions in the electronics manufacturing industry.A substantial portion of these emissions can be eliminated at little to no cost through the implementation of energy-efficiency measures(EEMs).As shown in Exhibit 2,energy-efficiency improvements in asse

22、mbly lines can reduce overall supply chain emissions by up to 20%,with abatement costs ranging from approximately-US$100 to US$0 per ton of CO2e by 2030.i Business cases from leading electronics companies demonstrate that EEMs can achieve up to 30%energy savings in existing facilities,significantly

23、reducing energy demand.This cost-effective opportunity represents one of the most impactful strategies electronics manufacturers can use to address their Scope 3 emissions.Exhibit 2 Abatement costs vs.abatement potential in the electronics supply chainRMI Graphic.Source:Net-Zero Challenge:The Supply

24、 Chain Opportunity,World Economic Forum,2021iNegative abatement costs indicate opportunities to reduce emissions while achieving a net economic gain.6%29%30%33%61%61%77%81%82%83%85%90%CementElectronicsMiningAutomotiveSteelConstruct.AgricultureFoodTextilesFashionChemicalsRaw materialsEnd productsFMCG

25、Supply chain(Scope 3 upstream)Consumed power etc.(Scope 2)Operations(Scope 1)4002000-200Abatement costs(US$/t CO2e,2030)100%Abatement potential(t CO2e,2030)Renewable power for assembly linesHydrogen in mining opsEnergy efficiency for assembly linesrmi.org/7Towards Net-Zero Electronics:Unlocking the

26、power of energy efficiency in manufacturing facilitiesIn addition,energy efficiency can significantly lower costs for manufacturers by reducing energy consumption and optimizing production processes.By investing in energy-efficient equipment such as advanced motors,lighting systems,and automated con

27、trols,manufacturers can reduce their overall energy consumption,resulting in lower utility bills.In addition,energy-efficient machines often last longer and require less maintenance,reducing downtime and costs for repairs.According to IEA,most EEMs in its Net Zero Scenario are already cost-effective

28、,meaning that the energy cost savings are greater than the investment required.6 According to the US Department of Energy,the average energy cost savings identified by an energy-efficiency audit of a single energy-intensive system within a manufacturing company is US$1.4 million;for small and midsiz

29、ed manufacturing companies,the average energy cost savings is US$165,000 per audit.7Managing energy efficiency in final assembly,testing,and packaging(FATP)facilitiesAn FATP facility is a manufacturing plant where the final stages of product assembly take place,including assembling components,testin

30、g the product to ensure it functions properly,and packaging it for shipment.FATP facilities are often associated with electronics manufacturing,for instance,of smartphones and computers.Although FATP facilities do not represent the most energy-and emissions-intensive stage of the electronics manufac

31、turing process,they are important for energy management in several ways,including:Experience gained from addressing energy efficiency at an FATP facility can easily be scaled up to other facilities with standardized systems.An FATP facility typically has several standardized systems,such as those fo

32、r compressed dry air(CDA)and heating,ventilation,and air conditioning(HVAC),that are commonly used in other manufacturing processes and facilities.For example,CDA systems are major energy consumers in the industrial sector,accounting for about 10%of industrial electricity consumption in the European

33、 Union and China,and 9%in the United States,Malaysia,and South Africa.8FATP is the stage at which an original equipment manufacturer(OEM)has direct control.FATP facility owners can therefore form better energy-efficiency collaborations and programs with OEMs and achieve optimal efficiency results,co

34、mpared with more upstream(indirect)suppliers,which OEMs typically cannot directly manage.Electricity is the main source of energy consumed by FATP.Energy consumption in these facilities is dominated by three major systems:production,HVAC,and process air(see Exhibit 3):The production system is the la

35、rgest energy consumer at 32%.In FATP facilities,this includes the final assembly of electronics(e.g.,surface mount technology SMT and through-hole assembly),testing,and packaging of devices.These operations require substantial energy for powering production machinery(e.g.,a reflow oven)and testing e

36、quipment.The HVAC system,accounting for about 30%of total energy consumption,includes air conditioning,ventilation,and temperature control across the facility.It ensures optimal working conditions by regulating temperature and humidity,as well as the number of particles,particularly in critical area

37、s like production lines and office spaces.The process air system consists of CDA,nitrogen,and other gases essential for production processes,accounting for 28%of the facilitys energy consumption.These systems are necessary for various support operations,such as surface treatment,spraying,and blowing

38、.rmi.org/8Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesThe remaining 10%covers other systems,such as lighting,office operations,and support services,which are essential for daily facility operations but contribute less to overall energy demand.Exhi

39、bit 3 Typical energy consumption breakdown in FATP facilitiesRMI Graphic.Source:RMI analysisImproving energy efficiency in FATP facilities faces several challenges.The complexity of these facilities,which include diverse operations and equipment,complicates the integration of energy-efficient techno

40、logies without disrupting ongoing processes.Additionally,the high costs associated with upgrading machinery and implementing energy-saving measures make it difficult to justify investments and demonstrate a clear return on investment.Moreover,optimizing processes to enhance energy efficiency while m

41、aintaining high product quality and adhering to regulatory standards adds another layer of difficulty.Addressing these challenges requires a strategic approach that balances technological advancements,cost considerations,and operational efficiency.10%32%28%30%Solder paste printingPreprocessingPackin

42、g material preparationInspectionPlacementLabelingSealingAssembly(manual,automatic)TestingReflow OvenTestingSMT ProcessFinal assembly&testingTypical energy consumption breakdown in FATP facilitiesPackagingHVAC systemProcess air system(incl.CDA,nitrogen,vacuum)Lighting&other facility appliances(e.g.,P

43、Cs,monitors)FATP Production ProcessSupporting infrastructuresHVAC systemFATP production processLighting&other facility appliancesProcess air systemrmi.org/9Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilities2.Retrofitting Existing Facilities for Energy E

44、fficiencyFor existing FATP facilities,enhancing energy efficiency is increasingly critical.Many of the worlds largest FATP facilities,particularly those built in China 1020 years ago,face urgent needs for comprehensive energy upgrades and equipment modernization.This urgency is amplified by the grow

45、ing commitment of OEMs to carbon neutrality within the electronics industry,including the decarbonization of their Scope 3 emissions.Additionally,tightening global and local standards and regulations are imposing stricter energy-efficiency requirements(see Exhibit 4).Internationally,standards such a

46、s ISO 50001 and ISO 50004 outline best practices for implementing an effective energy management system(EMS).In China,updated national and industry-specific standards reflect more stringent design requirements for factories.Regional or local governments have also proposed incentive policies,such as

47、awards for efficiency projects and action plans,to catalyze implementations by local manufacturers.Exhibit 4 Existing standards for energy management and green factoriesNameDescriptionGlobalISO 50001:2018EMS requirements with guidance for use:international standard that provides a framework for esta

48、blishing,implementing,maintaining,and improving an EMSISO 50004:2020Guidance for the implementation,maintenance,and improvement of an ISO 50001 EMS:provides practical advice and strategies on how to effectively implement,maintain,and improve an energy management system based on ISO 50001Chinas natio

49、nal standards&policiesGB/T 23331-2020Chinese version of ISO 50001:2018GB 51245-2017Unified standard for energy efficiency design of industrial buildingsGB/T 36132-2018General principles for assessment of green factoriesGB/T 50878-2013Evaluation standard for green industrial buildingsAssociation stan

50、dards in ChinaSJ/T 11744-2019Guideline for assessment of green factories in electronic information products manufacturing (issued by Ministry of Industry and Information Technology on November 11,2019)T/AIAC 003-2023Evaluation standard of zero-carbon factories(issued by Investment Association of Chi

51、na on May 28,2023)T/CIECCPA 030-2023General principles for implementation and assessment of zero-carbon factories(issued by China Industrial Energy Conservation and Clean Production Association on July 25,2023)T/CECA-G 0171-2022Evaluation specification of zero-carbon factories(issued by China Energy

52、 Conservation Association on 2022-6-1)RMI Graphic.Source:RMI analysisrmi.org/10Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesOptimizing the energy efficiency of existing FATP facilities involves a structured process consisting of several key steps(s

53、ee Exhibit 5).The first step is to conduct an energy audit to confirm baseline electricity consumption and define project boundaries.This is followed by a project investigation,in which on-site inspections are conducted to identify and document potential improvement projects and collect baseline dat

54、a for each proposed improvement.The next phase is project implementation and acceptance,during which project proposals are evaluated,retrofit plans are submitted,and projects are executed according to the established schedule.Finally,savings measurement and verification are performed to collect post

55、-implementation data and calculate the actual energy savings achieved.This structured process was developed with reference to the ISO 50001 and aligns with the Plan-Do-Check-Act framework,ensuring that energy-efficiency improvements are systematically planned,implemented,monitored,and continuously o

56、ptimized for long-term impact.Exhibit 5 General process for optimizing energy efficiency for existing FATP facilities RMI Graphic.Source:RMI analysisKey considerations in an energy auditBefore initiating any retrofit work,establishing a clear energy baseline through a comprehensive energy audit of t

57、he FATP facility is essential.This audit provides a critical understanding of current energy consumption situations and identifies improvement opportunities.Key considerations for an effective energy audit include:Comprehensive coverage of key energy consumers:The audit must encompass all major ener

58、gy-consuming elements of the facility,including production lines,processes,and equipment.Employing advanced diagnostic tools,such as thermal imaging and real-time energy monitoring,enhances the accuracy and depth of the audit.These tools help uncover hidden inefficiencies and establish a detailed ba

59、seline for subsequent energy-efficiency improvements.A focus on energy-intensity mapping:Energy consumption can vary significantly based on the product,process,and external factors,such as climate.Therefore,the audit should emphasize energy intensity,which is the amount of energy consumed per unit o

60、f production.This focus allows for precise comparisons and better identification of areas where energy efficiency can be improved.Energy AuditProject InvestigationProject Implementation&AcceptanceSavings Measurement&Verification Define clear boundary for project implementation Confirm baseline annua

61、l energy consumption of different systems and processes Establish clear and actionable goals Conduct on-site inspections to identify projects Collect pre-improvement data for each system Develop improvement plans for each project Submit improvement plans for approval Implement projects according to

62、the design plan Conduct final inspection and acceptance Collect post-improvement data Calculate energy savingsrmi.org/11Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesStakeholder engagement:Engaging key stakeholders,including facility operators,maint

63、enance teams,and management,is crucial.This involvement helps identify nontechnical barriers,such as operational practices and staff behavior,and ensures that the proposed EEMs are practical and have strong support for implementation.Clearly outlining the boundaries for the audit and specifying whic

64、h systems and processes will be evaluated is essential for a successful energy audit.Depending on the facilitys needs,energy assessments can vary in scope and depth,ranging from quick assessments that identify major opportunities,to detailed assessments of specific systems(e.g.,HVAC,CDA,lighting),or

65、 comprehensive plant-wide audits.While quick or system-specific assessments may be appropriate in certain situations,a plant-wide energy audit is highly recommended whenever possible.This comprehensive approach not only measures the energy consumption of individual systems but also maps the energy f

66、low between different components within the facility,uncovering broader opportunities for efficiency improvements.By analyzing the interactions between systems,the audit can identify additional energy-saving opportunities that might otherwise be overlooked.For instance,assessing the potential for he

67、at recovery and reuse between production processes and HVAC systems can reveal significant efficiency gains that would be missed if the HVAC or production systems were audited separately.A facility-wide audit also ensures that energy losses at system boundaries are captured and that the potential sy

68、nergies among various processes such as using waste heat from CDA systems for water heating are fully realized.In addition,after completing the energy audit,it is essential to establish clear,actionable goals for the energy-efficiency project.These goals should be designed to not only achieve energy

69、 and cost savings but also to deliver broader,lasting benefits to the facility and organization.Key advantages of such goals include enhancing the companys financial stability and improving its competitive position.Moreover,the energy-efficiency project should be implemented in a manner that maintai

70、ns operational security,ensuring seamless integration with existing production processes without causing disruptions.This careful approach allows the facility to sustain energy-efficiency improvements while safeguarding production quality and operational continuity.Systems investigation for optimal

71、energy-saving potentialBased on the energy intensity mapping results,the next step is to identify and evaluate EEMs for the most energy-intensive systems within the FATP facility.This includes a detailed assessment of potential improvements for key energy-consuming systems,such as HVAC systems,proce

72、ss air systems(including CDA,nitrogen,and vacuum),production processes,and other supporting equipment like lighting and personal computers(PCs).RMIs analysis of verified energy-saving data from over 30 China-based FATP facilities in the consumer electronics sector(e.g.,smartphones,laptops)reveals th

73、at the process air and HVAC systems present the highest potential for energy savings,accounting for an average of 43.5%and 36.8%of total energy reduction through EEM implementation,respectively.Although production equipment is the largest energy consumer,the potential for energy-efficiency improveme

74、nts is comparatively limited.Significant energy-savings potential also exists in other equipment,contributing to an average of 12.5%of total energy savings,despite accounting for only about 10%of total energy consumption(as shown in Exhibit 6).rmi.org/12Towards Net-Zero Electronics:Unlocking the pow

75、er of energy efficiency in manufacturing facilitiesExhibit 6 Energy consumption breakdown and subsystems contribution to total energy reduction in FATP facilitiesNote:The data analyzed represents averaged values across more than 30 FATP facilities.Actual energy-savings potential may vary significant

76、ly because of differences in production lines,facility construction years,equipment specifications,and other operational factors across individual facilities.RMI Graphic.Source:RMI analysis.When considering energy-efficiency improvements,FATP facility owners should assess several critical factors:(1

77、)the potential energy savings of each measure,(2)the payback period to determine whether the investment is financially viable,and(3)the operational impact to ensure that the measures minimally affect the production processes.By carefully evaluating these aspects,FATP facility owners can make informe

78、d decisions that enhance energy efficiency while maintaining operational effectiveness.Process air systemThe process air system at an FATP facility,which includes CDA,vacuum,and nitrogen,is a significant energy consumer,accounting for approximately 30%of the facilitys total electricity consumption.T

79、he process air system is also the most common area for energy-efficiency improvement,according to RMIs interviews with several companies.This system is critical to various manufacturing processes,providing essential functions,such as powering pneumatic tools,maintaining controlled environments,and s

80、upporting critical operations.Given its integral role in the production process,it is important to carefully balance EEMs with the need to ensure production reliability(see Exhibit 7,page 14).28%30%32%10%Total energy reduction through energy efficiency improvementTotal energy consumptionProcess air

81、system(CDA,vacuum,nitrogen)HVAC systemProductionequipmentOther(lighting,PCs,etc.)43.5%36.8%7.2%12.5%rmi.org/13Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilities1.CDA system:Compressor:The compressor is the central component of the CDA system.Upgrading f

82、rom low-efficiency compressors to high-efficiency models can substantially reduce energy consumption,with a payback period extending up to seven years.Alternatively,recovering waste heat from compressors is a more cost-effective measure,offering a payback period of under three years.iiDryers and val

83、ves:Implementing lossless dryers and drains can lower site energy consumption by up to 1.4%,with a payback period of less than three years.Additionally,installing an aftercooler before air dryers in refrigerated systems and extending dryer regeneration times through precise dew point control are cos

84、t-effective EEMs because of their minimal initial investment and substantial long-term savings.Air inlet and outlet:Optimizing air intake by repositioning and resizing suction ports can reduce compression energy consumption with minimal up-front investment.Furthermore,employing energy-saving air gun

85、s can cut unnecessary energy use with a payback period of less than one year.Pipeline:Detecting and repairing leaks,replacing pipeline connectors,and optimizing piping layouts(such as creating loop connections)are cost-effective,easily implemented EEMs.These improvements typically offer a payback pe

86、riod of less than six months,making them an attractive option for immediate energy savings.Control:Improving the control strategy of the CDA system is key to enhancing efficiency.Key measures include minimizing system pressure,optimizing compressor cycles,and implementing multiple-compressor control

87、s.Variable frequency drives(VFDs)can further reduce energy waste by adjusting air output to real-time demand.Installing local boosters for equipment requiring higher pressure helps avoid raising system-wide pressure.Additionally,interlocking dryers with compressors and shutting down unloaded compres

88、sors can reduce operational hours.These control strategies can cut site energy consumption by up to 1.5%,with a payback period of under two years.2.Vacuum system:Upgrading from vacuum generators to vacuum pumps and adopting more energy-efficient vacuum generators can significantly reduce energy cons

89、umption,with a typical payback period of less than two years.Furthermore,decreasing vacuum usage by reducing operational hours or replacing vacuum functions with mechanical alternatives,such as grippers,enhances efficiency and generates additional energy savings.3.Nitrogen system:Detecting and repai

90、ring leaks within the nitrogen system is essential for maintaining operational efficiency and preventing unnecessary energy consumption.Additionally,optimizing programmable logic controller settings ensures that the nitrogen system operates only as required,thereby reducing overall energy use.iiAll

91、payback period data and estimates are based on practical experience from real-world cases.In individual cases,the actual payback time can vary significantly,as it depends on various factors,such as electricity prices,heat recovery potential,and other site-specific conditions.rmi.org/14Towards Net-Ze

92、ro Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesExhibit 7 System diagram and energy-efficiency measures for a process air systemSystemEEMs1.CDA system1.1 Air compressor Replace low-efficiency air compressors Recover waste heat from air compressors1.2 Dryers and val

93、ves Install lossless dryers&drain valves Install aftercooler before air dryer(for refrigerated dryers)Prolong dryers regeneration time(e.g.,implement dew point control)1.3 Air inlet&outlet Reposition and resize suction port Use energy-saving air guns1.4 Pipeline Detect and repair leakage Replace pip

94、eline connectors Optimize pneumatic network1.5 Control Adjust system pressure(install booster pump for higher pressure when needed)Install VFD to regulate screw compressor Reduce running hours(e.g.,interlock dryers with compressor,shut down unloaded compressor,reduce CDA usage)2.Vacuum Replace vacuu

95、m generators with vacuum pumps Use more efficient vacuum generators Reduce vacuum usage(e.g.,reduce running hours,replace with grippers)3.Nitrogen Detect and repair leakage Optimize programmable logic controller(PLC)for nitrogen productionRMI Graphic.Source:RMI analysisAir gunsAir compressor 1.11.21

96、.51.3Air intakeAftercoolerAir receiverAir dryerMoisture separator and drain trapDistributorHigher CDA pressure equipmentVacuum generatorNitrogen1.423Cooling waterAir flowWater flowrmi.org/15Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesHVAC systemTh

97、e HVAC system is another major energy consumer in FATP facilities,typically accounting for approximately 30%of total electricity consumption.This figure can escalate considerably if the system is not properly configured and controlled.The HVAC system is crucial for maintaining optimal environmental

98、conditions within the facility,such as temperature,humidity,and air quality,which are essential for ensuring the reliability and quality of production processes.Given the HVAC systems significant energy use and critical role in production,it is important to implement key EEMs for each subsystem(see

99、Exhibit 8,page 16).1.Chiller:The chiller is a pivotal component of the HVAC system,significantly influencing overall energy efficiency.Upgrading from low-efficiency to high-efficiency chillers can substantially improve system performance,although the initial investment may result in a payback period

100、 ranging from two to over ten years.Conversely,regular cleaning of heat exchangers is a cost-effective measure that generally yields a payback period of less than two years.Additionally,selecting chillers with low global warming potential and ozone-depleting potential helps reduce life-cycle environ

101、mental impacts.2.Chilled and cooling water system:Over 20%of HVAC energy consumption is allocated to water transmission.Implementing straightforward and economical EEMs,such as insulating pipelines,increasing chilled water temperatures,and making hydraulic adjustments,can enhance efficiency.Addition

102、ally,using cooling towers for free cooling during colder months proves to be highly cost-effective,with a payback period of under two years.Upgrading to efficient VFDs for pumps typically results in a payback period of less than three years.3.Air-handling system:The air-handling system is particular

103、ly energy-intensive because of the stringent air-quality requirements necessary for electronics manufacturing.Cost-effective EEMs,including adjusting fresh air intake,regularly cleaning or replacing coils,and upgrading fan-filter units(FFUs)from AC to DC motors,usually offer a payback period of less

104、 than two years.Although exhaust-air heat recovery can be highly beneficial,the payback period may extend to four years or more,depending on specific conditions.Replacing steam humidifiers with spray or ultrasonic humidifiers is another effective measure,with a payback period of less than three year

105、s.4.Control system:In FATP facilities,where cooling demands fluctuate and system interactions are complex,the control system is essential for optimizing component efficiency and adapting to real-time needs.Installing VFDs on pumps and fans and employing time switches to reduce operational hours are

106、straightforward measures with a typical payback period of under three years.Although implementing centralized control through an EMS involves a higher level of complexity,it can greatly optimize HVAC operations across the facility,offering a payback period of less than two years because of significa

107、nt energy savings.5.Boilers:FATP facilities in colder climates often use boilers for space and water heating.Recovering waste heat from these systems can result in significant energy savings,provided that suitable heat sinks,such as dormitories or low-temperature processes,are identified for effecti

108、ve use.Other EEMs for boilers include installing flue gas sensors and controls to optimize combustion and replacing leaking steam traps.Improving boiler efficiency can reduce energy consumption by up to 30%,with payback periods of less than two years.Furthermore,transitioning from fossil-fueled boil

109、ers to electric heat pumps can significantly lower direct CO2 emissions and provide additional benefits,such as reduced local air pollution(SOx,NOx)and lower insurance costs.Thanks to the excellent energy efficiency of heat pumps and the decreasing electricity prices relative to fossil fuels,the ini

110、tial investment in heat pump technology can typically be recouped within five years.rmi.org/16Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesExhibit 8 System diagram and energy-efficiency measures for HVAC systems SystemEEMs1.Chiller Replace low-effi

111、ciency chillers with high-efficiency models Clean heat exchanger2.Water system Optimize cooling water quality(e.g.,add disincrustant,change filters)Install temperature sensors on cooling towers for on/off control Use cooling towers for free cooling,where feasible Increase the chilled water temperatu

112、re Optimize the hydraulic system Replace less efficient pumps3.Air-handling system Adjust the volume of the fresh air intake Clean or replace fan coils Upgrade clean room FFUs from AC to DC motors Incorporate heat recovery from exhaust air Replace steam humidifiers with spray or ultrasonic humidifie

113、rs Replace less efficient fans(including exhaust fans,fans in AHU,etc.)4.Control Install VFD controls on pumps and fans Implement centralized control through an EMS Reduce running hours(e.g.,by using time switches)5.Boiler Recover waste heat(install economizer,add heat recovery units for flue gas an

114、d condensate water)Install flue gas sensor and controller in boiler Replace leaking steam traps Replace boilers with heat pumps6.Passive measures Add insulation to chilled water pipes Insulate or reposition heat-generating equipment(e.g.,oven exhaust gas ducts)RMI Graphic.Source:RMI analysisChiller3

115、Cooling towerFanPumpsPumpsCooling water systemChilled water systemWater system154CondenserEvaporatorProduction processAir compressorCompressorBoilerAir handling unitsFFUClean roomAir handling unitsExhaust airAir flowWater flow2rmi.org/17Towards Net-Zero Electronics:Unlocking the power of energy effi

116、ciency in manufacturing facilitiesProduction systemThe production process accounts for approximately 30%of total electricity consumption for FATP facilities.This process is critical as it has a direct impact on the manufacture of electronic components and the overall efficiency of manufacturing oper

117、ations.However,the implementation of EEMs in this area is often driven by OEM specifications,which limit the flexibility of suppliers to make changes.In addition,because much of the energy consumption in this process is closely tied to production activities,introducing EEMs could disrupt operations

118、or introduce uncertainty.Despite these challenges,several strategies can improve energy efficiency in the manufacturing process(see Exhibit 9,page 18).Standby mode optimization:Production processes are not continuous,and research shows that 30%of energy consumption by machine tools comes from standb

119、y operation during production pauses or equipment idle periods.9 Optimized energy-saving modes can help avoid unnecessary energy waste by automatically reducing power consumption when equipment is not in active use.This measure is highly cost-effective,as it typically requires little to no up-front

120、investment while delivering immediate energy savings.Insulation:Many production processes generate excess heat that is often lost to the environment.Properly insulating equipment and heat-emitting areas helps retain this heat,reducing the workload on HVAC systems.This measure requires minimal up-fro

121、nt investment while delivering considerable energy savings;the payback period is typically less than six months.Process automation:Process automation can enhance overall efficiency by optimizing workflows,reducing manual intervention,and minimizing energy use across various stages of production.For

122、instance,replacing pneumatic systems with servo motors could offer greater precision and efficiency,as well as reduce the CDA systems energy consumption.Although automation requires up-front investment,the energy savings,along with improved productivity and reduced manual labor costs,result in a hig

123、her return on investment over time.In addition,replacing outdated,less efficient monitors used on production lines presents an often-overlooked opportunity for substantial energy savings.Newer,energy-efficient monitors consume significantly less power during active use and offer enhanced energy-savi

124、ng modes that automatically reduce energy consumption when not in use.This dual benefit lower energy consumption in active and standby phases can yield considerable energy savings across the facility,especially in high-density production environments with numerous operating monitors.rmi.org/18Toward

125、s Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesExhibit 9 Main FATP production processes and energy-efficiency measuresSystemEEMs1.SMT process Use central chilled water for reflow oven cooling Improve reflow oven insulation Introduce or optimize energy-savi

126、ng mode for production equipment2.Testing Replace less efficient split air conditioners for burn-in test Replace less efficient testing equipment3.Final assembly Replace less efficient robot grippers Introduce or optimize energy-saving mode4.Packaging Replace shrink wrap with rip cord Improve shrink

127、 wrap machine insulation5.Overall Replace less efficient monitors used on production linesRMI Graphic.Source:RMI analysisScreen printingPick&placeReflow ovenBare boards&laser markingManual&through hole assemblyTestingFinal assemblyPackagingSolder paste inspectionVisual inspectionAutomated optical in

128、spection1234SMT Processrmi.org/19Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesLighting and other facility appliancesLighting is typically the next largest energy-consuming activity in FATP facilities,following HVAC systems,air systems,and productio

129、n processes.Because of its widespread use across the facility,lighting presents significant opportunities for energy savings.Common EEMs include installing high-efficiency LED fixtures and integrating controls such as motion sensors and time switches to ensure lights are activated only when necessar

130、y.Additionally,implementing task lighting in specific areas,such as testing zones,can reduce the need for general overhead lighting throughout the facility,thereby enhancing overall efficiency.These lighting EEMs are generally cost-effective,often resulting in a payback period of less than two years

131、.Other facility appliances include office devices such as PCs,monitors,split air conditioners,and drinking water dispensers,as well as supporting equipment like elevators.Although these appliances are not the primary energy consumers in FATP facilities,notable energy savings can be achieved by repla

132、cing inefficient equipment with high-efficiency models and minimizing unnecessary use,such as turning off monitors and drinking water heaters during off-hours(Exhibit 10).Although these behavioral EEMs require minimal investment,they do require staff training,education,and communication.Exhibit 10 E

133、nergy efficiency measures for lighting and other facility appliancesSystemEEMsLighting Replace less-efficient lamps with high-efficiency LEDs Install lighting sensors and time switches Evaluate and optimize lighting for specific areasOther facility appliances Replace less efficient split air conditi

134、oners(e.g.,split air conditioners for offices or testing)Replace less efficient PCs and monitors Turn off drinking water machines during off-hoursRMI Graphic.Source:RMI analysisrmi.org/20Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesCase Study:Achie

135、ving over 30%energy savings through EEM implementation in an FATP facilityA comprehensive energy-efficiency program enabled a leading electronics manufacturer to achieve over 30%energy savings in one of its FATP facilities(see Exhibit 11).HVAC system optimizations led the way,contributing nearly 42%

136、of total energy savings,with control enhancements such as VFDs for pumps and fans and an EMS saving approximately 5 million kilowatt-hours(kWh)annually(over 25%of total energy savings).Process air system improvements were the second-largest contributor,delivering 38.1%of total savings.Notably,replac

137、ing vacuum generators with vacuum pumps alone saved 2.6 million kWh annually,or 15%of the total energy saved in the facility.Lighting upgrades,mainly through illumination management,saved nearly 2 million kWh,while production processes offered smaller savings,contributing 4.2%(0.8 million kWh)of the

138、 total energy savings.This case study underscores the significant energy-saving potential of EEMs in FATP facilities,with HVAC and process air systems having the greatest impact.Exhibit 11 Contribution of different EEMs to total energy savings in an FATP facilityRMI Graphic.Source:RMI analysis60.060

139、50403020100-5.0-1.6-0.9-1.2-0.8-1.0-2.6-1.1-1.5-0.6-0.1-2.041.730%energy consumption reduction in total,with contributions from each systemBefore EEMsVacuumDryers&valvesAir compressorPipelineControl(CDA)Control(HVAC)Air handling systemWater systemProduction equipmentChillerLightingOther equipmentAft

140、er EEMsHVAC systemProcess air systemProductionOther42%38%16%4%Energy consumptions/savings(million kWh)rmi.org/21Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesProject implementation and acceptanceWhen implementing energy-efficiency projects in FATP f

141、acilities,several challenges need to be addressed.These include variations in project implementation times,the potential impact on production schedules,and the high up-front investment required for some EEMs.To overcome these challenges and ensure effective project execution,it is essential to focus

142、 on the following three key aspects:Strategically sequence the EEMs:Start by implementing simple and proven measures that are typically easy and cost-effective,providing quick wins and establishing a solid foundation for more complex upgrades.Find the right time for hard-to-implement projects:Schedu

143、le EEMs that require longer installation times and may disrupt production during periods that minimize production downtime,such as public holidays.Introducing high-efficiency equipment toward the end of the current product life cycle can maximize economic returns.Aligning new product introductions w

144、ith system upgrades can also help optimize energy efficiency.Leverage financial support:For larger projects,seek financial assistance through public funding,policy incentives,and energy performance contracting.These resources can help offset initial costs,making it more feasible to implement ambitio

145、us energy-saving measures.In a real-world case,leveraging government subsidies and recycling incentives reduced the initial cost of replacing low-efficiency motors by up to 65%.After the implementation,a rigorous acceptance phase is vital for confirming the success of the EEMs and ensuring sustained

146、 energy savings.This phase should involve thorough commissioning to verify that the newly installed systems integrate effectively with existing processes and meet performance expectations.Installing measurement devices during the retrofit process is also crucial for accurate future savings verificat

147、ion,ensuring that the benefits of the implemented measures are accurately tracked and maintained.Proactively seeking collaboration with OEMs can provide valuable support,especially when addressing complex implementation challenges.Suppliers are encouraged to work closely with OEM expert teams,who ca

148、n offer on-site assistance and insights into best practices.This collaboration can be instrumental in building internal capabilities,from developing specialized skills and forming dedicated teams to setting up robust systems and adopting proven methodologies.By leveraging OEM guidance and resources,

149、FATP facilities can streamline project execution,overcome potential obstacles,and achieve lasting gains in energy efficiency throughout the project life cycle.rmi.org/22Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesCase Study:OEM and supplier collab

150、orate for a successful energy-efficiency projectA leading consumer electronics OEM collaborated with its FATP supplier to undertake a comprehensive three-year energy-efficiency improvement project at the suppliers facility.During the preparatory phase,the two organizations established an ambitious t

151、arget of achieving 30%energy savings.This goal was informed by the suppliers thorough energy intensity mapping,the OEMs previous successes in energy-efficiency retrofits,and insights from external energy-efficiency experts.This initiative reflected a shared commitment to sustainability and continuou

152、s improvement from both parties.In the implementation phase,a joint working group was formed to facilitate technical support and training for the effective execution of the EEMs.The supplier created an internal team dedicated to securing essential resources,including funding and personnel,to ensure

153、the projects success.The focus was placed on critical areas such as HVAC systems,process air management,and the SMT production process.Key actions included the installation of group control systems for chillers and air compressors,VFDs for motors and pumps,and energy-efficient cooling systems for re

154、flow ovens.As a result of their strong collaboration and the effective implementation of EEMs,the project achieved a remarkable 35%reduction in energy consumption,surpassing the initial target.The OEMs sustainability commitment to supply chain decarbonization served as the primary motivation for ini

155、tiating the project,further strengthened by the close collaboration between the OEM and the supplier.For the supplier,the project reinforced its own sustainability goals while delivering operational efficiency improvements and significant cost savings.These benefits provide a compelling case to scal

156、e energy-efficiency initiatives both within the company and across the wider industry.Savings verificationA rigorous measurement and verification(M&V)process is crucial to the success of suppliers energy-efficiency programs,ensuring that energy savings are accurately quantified,validated,and sustain

157、ed across the supply chain.Implementing a standardized yet tailored M&V process is vital for accurately assessing the impact of EEMs.This process should be grounded in the International Performance Measurement and Verification Protocol(IPMVP)and should be recognized and agreed upon by all relevant s

158、takeholders,including OEMs,suppliers,external verifiers,and M&V experts.Aligning all parties on the methodology ensures that the M&V process serves as a dependable tool for validating energy savings and demonstrating the effectiveness of the implemented measures.Maintaining the credibility of the M&

159、V process necessitates defining acceptable deviation thresholds to ensure results fall within an agreed-upon range of accuracy.This precision is essential for correctly attributing observed energy savings to the implemented measures,thereby avoiding misinterpretation due to external factors or measu

160、rement errors.Establishing clear accuracy requirements helps maintain the integrity of the M&V process and ensure reliable outcomes.rmi.org/23Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesEngaging external auditors to independently verify the M&V re

161、sults adds an additional layer of credibility and reliability to the energy-efficiency program.External assurance not only validates the findings but also enhances the defensibility and scalability of the energy savings across the supply chain.By incorporating independent verification,the program ca

162、n gain greater trust and support from all stakeholders involved.Case Study:Using a rigorous M&V process to strengthen reputation and enable further improvementsA leading consumer electronics OEM collaborated with its FATP supplier to implement an IPMVP-based,high-accuracy,five-step approach to verif

163、y energy savings from an energy-efficiency project involving the installation of VFD controls.The initial energy savings measurement was performed by the suppliers facility management team.Following this,a third-party verifier was engaged to conduct a thorough remeasurement,resulting in a detailed v

164、erification report that outlined the project specifics,the M&V methodology employed,and the confirmed energy savings.To ensure the reliability of these findings,the results were subsequently reviewed by another third-party verifier,with all parties including the supplier,the OEM,and both verifiers c

165、ollectively approving the rigorously validated results.This consensus on the energy savings not only facilitated the broader implementation of the energy-efficiency project but also positioned it as a highlight in the companys ESG report,thereby enhancing its social and environmental reputation and

166、increasing attractiveness to investors.Additionally,the comprehensive M&V process allowed the supplier to uncover further energy-saving opportunities within the FATP facility,setting the stage for ongoing improvements in energy efficiency and reinforcing the commitment to sustainability.Exhibit 12 I

167、PMVP-based,five-step,high-accuracy approach to an M&V processNote:“Deviation”under Step 5 refers to the difference between expected and actual energy savings.Significant deviations should be explained in the M&V report.RMI Graphic.Source:RMI analysisAccuracy&sampling approachScope:project listSTEP 1

168、:AccuracyM&V methodology (remote/on-site data checklist）Field design&instructionSTEP 3:MethodologyProject tool(description,savings calculation methods,verified variable values)Clarification&additional dataSTEP 2:PrognosisOn-site/virtual data collection&verificationSTEP 4:Measurement M&V reportAssura

169、nceSTEP 5:RealizationProject readiness?Multi-partyconsistency?NYYYDeviation？rmi.org/24Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilities3.Planning for Optimum Energy Efficiency in New FacilitiesRetrofitting existing FATP facilities unlocks substantial e

170、nergy-efficiency improvements and provides valuable lessons for designing new FATP facilities.Although all the EEMs discussed in the retrofitting section apply to new facilities,constructing a new facility offers additional opportunities to achieve optimal energy efficiency from the outset.Starting

171、with a clean slate enables a holistic design approach,incorporating the latest energy-saving technologies and seamlessly integrating systems to maximize energy performance across the facility.Unlike retrofits,which often focus on incremental upgrades,new facilities can be designed for comprehensive,

172、long-term energy efficiency.An integrated design approach is crucial in this context,as it allows for a holistic consideration of the facilitys systems and processes.By treating the facility as a unified entity rather than a collection of disparate components,integrated design ensures that all eleme

173、nts work cohesively to maximize energy efficiency.This approach not only reduces energy consumption significantly but also enhances operational effectiveness and reduces waste,setting the foundation for sustainable operations in new FATP facilities.Key principles for new FATP facilities with an inte

174、grated design approachThe design of a new FATP facility necessitates the collaboration of diverse stakeholders,including architects,engineers,environmental consultants,and operational managers.Establishing a set of shared principles for integrated designing is crucial for harmonizing these varied pe

175、rspectives and expertise.This alignment ensures that all parties are oriented toward common goals of sustainability and efficiency,streamlining the decision-making process and enhancing the effectiveness of energy-efficiency strategies.The principles(see Exhibit 13)serve as a foundational guide to f

176、oster this collaborative approach and drive the successful implementation of effective and cohesive energy-efficiency solutions.Exhibit 13 Key principles for integrated design for new energy-efficient FATP facilitiesRMI Graphic.Source:RMI analysisrmi.org/25Towards Net-Zero Electronics:Unlocking the

177、power of energy efficiency in manufacturing facilitiesSelect energy-efficient and electric equipmentSelecting energy-efficient equipment is essential for optimizing energy performance in a new FATP facility.Choosing advanced,energy-efficient,and all-electric components such as heat pumps,air compres

178、sors,reflow ovens,and chillers with VFDs can significantly reduce energy consumption and eliminate direct emissions.For example,an air compressor with an energy-efficiency rating of 1 is approximately 20%more efficient than one with a rating of 3.iii Given that compressed air systems account for abo

179、ut 30%of total energy consumption in FATP facilities,this efficiency improvement translates into substantial energy savings.Prioritize passive technologyPassive technologies reduce a facilitys energy demand by harnessing natural resources,making them a key component of integrated design.By optimizin

180、g the buildings architecture,passive strategies enable natural heating,cooling,and lighting,thereby reducing dependence on mechanical systems.Research indicates that passive strategies can reduce cooling loads by 31%on average,significantly lowering energy demand.10 Additionally,the use of passive t

181、echnologies cuts life-cycle costs by allowing for smaller,less energy-intensive equipment.For instance,air-conditioning systems with 30%lower cooling capacity,made possible through passive design,are typically 10%cheaper,offering both up-front cost savings and long-term energy-efficiency benefits.De

182、ploy automation and smart controlsThe integration of automation and smart controls is a cornerstone of dynamic energy management within an integrated design approach.For instance,deploying smart HVAC controls that adjust heating and cooling based on real-time occupancy and demand can significantly r

183、educe energy consumption during nonpeak periods.Best practices show that combining VFDs with smart controls can reduce a chillers annual energy use by up to 30%.11 Furthermore,equipping production equipment with smart sensors and automated controls for standby and idle modes can optimize energy usag

184、e during production downtime,leading to additional efficiency gains.In one FATP facility,for instance,implementing an energy-saving mode for production equipment like reflow ovens resulted in a 1%reduction in the facilitys total energy consumption.Adopt modular and scalable equipmentDesigning facili

185、ties with modular and scalable equipment provides significant flexibility and adaptability in response to changing production requirements.For example,employing modular clean room,air-handling systems that can be expanded or contracted based on production demand helps prevent unnecessary energy cons

186、umption.Similarly,modular power distribution systems and scalable compressed air systems in FATP facilities enable use of only the energy necessary for current production loads,thereby reducing overall energy waste.Integrate emerging technologiesEarly integration of emerging technologies,such as AI-

187、driven energy management platforms and advanced cryogenic nitrogen generation systems,places new FATP facilities at the forefront of energy iiiAnalysis is based on Chinas national standard“minimum allowable values of energy efficiency and energy-efficiency grades for displacement air compressors(GB

188、191532019)”.Data for an oil-injected,rotary air compressor with a nominal discharge pressure of 0.7 MPa and nominal motor power of 22 kW is used for comparison.rmi.org/26Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesefficiency.Case studies show that

189、 AI technology can enable energy-efficiency improvement of 20%40%in the chemical industry.12 Within an integrated design framework,these technologies provide continuous energy usage optimization,crucial for maintaining long-term energy efficiency.By embedding these advanced technologies from the out

190、set,the facility is equipped to continually adapt and improve its energy strategies.Recover and reuse energyIncorporating energy recovery systems into new FATP facilities exemplifies integrated design by linking heat sources and sinks to maximize efficiency.This approach captures waste heat from pro

191、duction equipment for other needs,such as preheating HVAC intake air or providing hot water in canteens and dormitories.By repurposing otherwise wasted heat,these systems reduce overall energy consumption and costs.For example,70%80%of the electricity used by air compressors is converted to heat and

192、 released into the environment;capturing this waste heat for hot water could save about 0.6%of the facilitys total energy consumption.Case Study:Designing new energy-efficient FATP facilitiesA leading electronic components manufacturer adopted an integrated design approach to constructing a new FATP

193、 facility,emphasizing key principles for maximizing energy efficiency.Central to the design was the selection of energy-efficient equipment,which included high-performance chillers,air compressors,and motors rated at level 2 efficiency or higher.iv This strategic choice not only minimizes energy con

194、sumption but also enhances operational throughput,particularly through the deployment of energy-efficient pick-and-place machines in SMT processes.Additionally,the facilitys architecture incorporated advanced passive technologies,such as an optimized building envelope,which significantly reduces hea

195、t loss and maximizes natural lighting,thus lowering overall energy demand.The facilitys design further prioritized automation and smart controls to facilitate dynamic energy management.Extensive smart control systems were integrated,including VFDs for pumps and motors,along with occupancy sensors an

196、d timers for lighting and HVAC systems.This ensures that energy consumption is closely aligned with actual demand,minimizing waste during nonpeak periods.A centralized EMS seamlessly integrates these components,enabling intelligent sequencing and real-time monitoring to optimize energy usage across

197、the facility.A standout feature of the new FATP facility is its robust heat recovery system,designed to effectively use waste heat from air compressors for heating needs,such as hot water and mixed air units.By incorporating energy recovery systems from the outset,the facility exemplifies the essenc

198、e of integrated design,maximizing efficiency through the interconnectedness of various systems.These comprehensive energy-saving measures have not only resulted in the facilitys achieving LEED Gold certification for the entire manufacturing campus but also Chinas Green Factory certification,showcasi

199、ng the manufacturers commitment to sustainability and operational excellence.ivLevel 2 is the second highest(out of three)energy efficiency rating under Chinas national standards for various equipment types,such as chillers(GB 19577-2024)and air compressors(GB 19153-2019).rmi.org/27Towards Net-Zero

200、Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesImplementing integrated design:Key considerations for energy efficiency in new FATP facilitiesImplementing an integrated design approach in new FATP facilities involves prioritizing energy efficiency through cohesive wor

201、kflows.This approach requires a thorough understanding of the facilitys energy needs and the implementation of innovative solutions to meet those requirements.Traditional methods often treat essential energy needs such as heating,cooling,lighting,and process air through separate,stand-alone systems,

202、which can lead to missed opportunities for synergy and increased inefficiencies.By adopting an integrated design approach that harmonizes building layout with operational processes,energy demands can be met more effectively and sustainably.This section will focus on three critical workflows essentia

203、l to achieving energy efficiency:Building and facility layout design,which optimizes the physical configuration to enhance energy performance.This workflow is normally led by architects and building designers.System and equipment design,which strategically selects and arranges technologies to minimi

204、ze energy consumption while maximizing production efficiency.This workflow is normally led by mechanical engineers.Control and monitoring systems,which leverage advanced technologies to continuously manage and refine energy usage.This workflow is normally led by electrical engineers.Working together

205、,these workflows exemplify the integrated design approach,ensuring that all aspects of the facilitys design and operation work synergistically.This method not only addresses individual energy needs but also fosters a comprehensive strategy that significantly enhances the facilitys overall energy eff

206、iciency and sustainability.Building and facility layoutThe integrated design approach at the building design stage is essential for maximizing energy efficiency in FATP facilities by aligning physical spaces with energy needs and collaborating with other workflows.Strategic design decisions can grea

207、tly reduce energy consumption across various operational demands,enhancing the overall effectiveness of this holistic method.By considering the layout and functionality of the facility from the outset,designers can create an environment that supports optimal energy performance.In managing process ai

208、r,the facility layout should position air compressors close to their points of use to minimize distance,thereby reducing pressure drops and leakage.This design optimization not only cuts down on the energy required for air distribution but also integrates seamlessly with heating and cooling.Suggeste

209、d steps include:Implementing effective passive measures such as optimizing building orientation and shade,and using high-performance thermal insulation.This can significantly lower heating and cooling loads,directly affecting the energy demand on HVAC systems.Implementing an efficient piping layout

210、to minimize the energy required for distributing heated or cooled air,water,or recovered heat,thereby reducing pumping energy consumption.rmi.org/28Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesMaximizing natural daylight through strategic window pl

211、acements and skylights so that facilities can reduce reliance on artificial lighting,while reflective surfaces such as light-colored walls and ceilings can improve the distribution of natural light throughout the space,further minimizing the need for artificial lighting.Additionally,optimizing works

212、tation layouts and minimizing transportation distances between production stations,which can directly reduce electricity consumption for motion and transportation,leading to more efficient operations.System and equipmentSelecting systems and equipment with high energy-efficiency ratings is critical

213、for achieving the operational needs of new FATP facilities while maximizing energy efficiency.An integrated design approach during this selection process ensures that each system not only fulfills its functional requirements but also enhances overall energy use across interconnected workflows.Measur

214、es include:Using high-efficiency air compressors and related equipment in the process air system to reduce energy use significantly.Selecting high-efficiency chillers,boilers,and pumps for heating and cooling is essential.Additionally,using recovered heat from processes like air compressors and refl

215、ow ovens can effectively meet heating and cooling demands while minimizing energy waste.Employing centralized chilled water systems for critical processes that require cooling,such as reflow oven operations.This is recommended because of their higher efficiency compared with split systems.Choosing e

216、nergy-efficient production equipment,including reflow ovens and packaging machines.Additionally,using robotic grippers instead of vacuum systems where feasible can save energy otherwise consumed in vacuum generation.Furthermore,insulating heat-generating equipment such as reflow ovens improves the e

217、quipments efficiency while also reducing unnecessary cooling demand.Using LED fixtures along with targeted lighting layouts to ensure that illumination is directed precisely where it is needed.Control and monitoringA centralized EMS serves as the core of a new energy-efficient FATP facility,effectiv

218、ely coordinating the interactions among various systems and processes to maximize the energy-saving potential of each piece of equipment.This advanced system enables real-time energy monitoring,allowing for continuous optimization of energy use and the identification of inefficiencies across the fac

219、ility.By integrating dedicated controls for specific systems such as occupancy-based lighting switches this approach provides targeted energy savings at the process level,ensuring comprehensive management and persistent optimization of energy consumption throughout all facility operations.Recommenda

220、tions include:Implementing intelligent controls,including VFDs and automatic on/off control to improve the energy efficiency of process air systems.Advanced monitoring systems should track air pressure and temperature to optimize airflow and ensure that equipment operates only when needed.rmi.org/29

221、Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesInstalling a centralized control system equipped with VFDs,compressor group controls,and advanced valves for air and water flow management to significantly enhance overall heating and cooling efficiency.

222、These controls intelligently adjust based on real-time heating and cooling demands,thereby improving the facilitys energy performance.Integrating lighting controls with sensors such as motion detectors and daylight sensors which can significantly enhance efficiency by automatically adjusting light l

223、evels based on occupancy and natural light availability.Centralized control systems further optimize lighting management by allowing for facility-wide adjustments.Incorporating energy-saving modes for idle equipment and prioritizing the use of efficient motors during operation to substantially reduc

224、e electricity consumption.These measures ensure that energy is used only when truly needed,contributing to overall efficiency.Key considerations for implementing integrated design for energy efficiency in new FATP facilities are summarized in Exhibit 14(page 30).Major energy consumers HVAC systems,p

225、rocess air systems,manufacturing systems,and lighting systems are interrelated and can either complement or hinder one anothers efficiency,depending on how they are designed and integrated.By adopting an integrated design approach that considers the entire facility,FATP manufacturers can optimize en

226、ergy efficiency,reduce operating costs,and advance sustainability goals.rmi.org/30Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesExhibit 14 Integrated system design considerations for energy-efficient FATP facilitiesEnergy-dependent operational needs

227、 in FATP facilitiesGas or district heatingElectricityHeating/CoolingLightingProcess air (including CDA,nitrogen,vacuum)Electricity used by production equipmentBuildings and Facility LayoutProduction Hall DesignOptimize building orientation and shadeUse thermal insulation and airtight envelopeDesign

228、for natural light (orientation,window,reflective surfaces)Optimize workstation and facility layout to reduce energy use for motion and transportationFacility Layout Design(entire complex,including production halls,warehouses,dormitories,canteen)Optimize facility layout to reduce pump energy(e.g.,coo

229、ling water&recovered heat transmission)Optimize facility layout to reduce air distribution energySystems and EquipmentHVAC SystemUse high-efficiency equipment(compressors,pumps,fans,FFUs)Configure the quantity and capacity of chillers for optimal working efficiencyConsider heat pumps when heating an

230、d cooling demand both existReuse waste heat from exhaust air(e.g.,for fresh-air pre-conditioning)Lighting Use high-efficiency LEDs with smart sensorsOptimize lighting layoutProcess Air System (including CDA-system,vacuum and nitrogen generation and supply)Recover waste heat from air compressorUse re

231、covered heat for air dryersUse high-efficiency cooling equipment for aftercoolerUse high-efficiency equipment(compressor,dryers,air guns,vacuum pumps)Set system pressure properlyOptimize pneumatic network for less air leakagePosition air inlet correctly for better air qualityProduction ProcessInsula

232、te heat-generating equipment(e.g.,reflow oven)Recover waste heat(e.g.,from forming,molding process)Use centralized chill water for reflow oven coolingUse robot gripper instead of vacuum,when possibleUse high-efficiency equipment(e.g.,reflow oven,packaging machine)Streamline the production process to

233、 reduce energy use(lean manufacturing)Control and Monitoring Systems(e.g.,EMS)Install centralized control system(incl.VFD control,compressor group control,valves for water/air volume control)Integrate lighting control systems(timer,occupancy,etc.)Install intelligent compressor system(including VFD c

234、ontrol,on/off control)Optimize energy-saving mode when equipment is idlingRMI Graphic.Source:RMI analysisWhat can be optimized when designing new FATP facilitiesrmi.org/31Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilitiesEndnotes1Consumer Electronics Ma

235、rket,Research and Markets,2024.22024 China Electronics Industry Supply Chain Development Report,China Federation of Logistics and Purchasing,2024.3Sustainable Electronics Manufacturing,20232033,IDTech,2022.4How Energy Efficiency Will Power Net Zero Climate Goals,IEA,2021.5 Steve Chen,Apoorv Gautam,a

236、nd Florian Weig,Bringing Energy Efficiency to the Fab,McKinsey&Company,2013.6 The Value of Urgent Action on Energy Efficiency,IEA,2022.7 Energy-Saving Opportunities for Manufacturing Enterprises,US Department of Energy,2011.8 J.J.Cabello Eras,A.Sagastume Gutirrez,V.Sousa Santos,and M.J.Cabello Ulloa

237、,“Energy Management of Compressed Air Systems.Assessing the Production and Use of Compressed Air in Industry,”Energy 213,2020.9Energy Efficiency in Production:Future Action Fields,Fraunhofer Gesellschaft.10M.Hu,K.Zhang,Q.Nguyen,and T.Tasdizen,“The Effects of Passive Design on Indoor Thermal Comfort

238、and Energy Savings for Residential Buildings in Hot Climates:A Systematic Review,”Urban Climate 49,2023.11VSD Chillers Deliver Energy Savings under Real World Operation,Chiller and Cooling Best Practices,2017.12Rohit Kochar,“AI Will Transform Chemical Industries for Better Energy Management”,Chemica

239、l Industry Digest,2023.Wei Li,Guangxu Wang,and Meng Wang,Towards Net-Zero Electronics:Unlocking the power of energy efficiency in manufacturing facilities,RMI,2025,https:/rmi.org/insight/towards-net-zero-electronics/.RMI values collaboration and aims to accelerate the energy transition through shari

240、ng knowledge and insights.We therefore allow interested parties to reference,share,and cite our work through the Creative Commons CC BY-SA 4.0 license.https:/creativecommons.org/licenses/by-sa/4.0/All images used are from iStock unless otherwise noted.RMI Innovation Center22830 Two Rivers RoadBasalt,CO 81621www.rmi.org April 2025 RMI.All rights reserved.Rocky Mountain Institute and RMI are registered trademarks.