Energy efficiency (EE) improvement is one of the most crucial elements in the decarbonization of industry. EE potential within industries largely remains untapped due to the lack of information regarding potential EE measures (EEM), knowledge regarding energy use, and due to the existence of some inconsistencies in the evaluation of energy use. Classification of energy end-using processes would increase the understanding of energy use, which in turn would increase the detection and deployment of EEMs. The study presents a novel taxonomy with hierarchical levels for energy end-use in manufacturing operations for the engineering industry, analyzes processes in terms of energy end-use (EEU) and CO2 emissions, and scrutinizes energy performance indicators (EnPIs), as well as proposing potential new EnPIs that are suitable for the engineering industry. Even though the study has been conducted with a focus on the Swedish engineering industry, the study may be generalizable to the engineering industry beyond Sweden.

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Increasing energy efficiency within the industrial sector is one of the main approaches in order to reduce global greenhouse gas emissions. The production and processing of aluminium is energy and greenhouse gas intensive. To make well-founded decisions regarding energy efficiency and greenhouse gas mitigating investments, it is necessary to have relevant key performance indicators and information about energy end-use. This paper develops a taxonomy and key performance indicators for energy end-use and greenhouse gas emissions in the aluminium industry and aluminium casting foundries. This taxonomy is applied to the Swedish aluminium industry and two foundries. Potentials for energy saving and greenhouse gas mitigation are estimated regarding static facility operation. Electrolysis in primary production is by far the largest energy using and greenhouse gas emitting process within the Swedish aluminium industry. Notably, almost half of the total greenhouse gas emissions from electrolysis comes from process-related emissions, while the other half comes from the use of electricity. In total, about 236 GWh/year (or 9.2% of the total energy use) and 5588–202,475 tonnes CO2eq/year can be saved in the Swedish aluminium industry and two aluminium casting foundries. The most important key performance indicators identified for energy end-use and greenhouse gas emissions are MWh/tonne product and tonne CO2-eq/tonne product. The most beneficial option would be to allocate energy use and greenhouse gas emissions to both the process or machine level and the product level, as this would give a more detailed picture of the company’s energy use and greenhouse gas emissions.