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Unit 12. Eco-selection and the Eco-audit tool Introducing students to life-cycle thinking

Unit 12. Eco-selection and the Eco-audit tool Introducing students to life-cycle thinking. Resources Text: “Materials and the Environment”, Chapters 1 - 9 Text: “ Materials: engineering, science, processing and design”, 2 nd Edition, Chapter 20

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Unit 12. Eco-selection and the Eco-audit tool Introducing students to life-cycle thinking

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  1. Unit 12.Eco-selection and the Eco-audit toolIntroducing students to life-cycle thinking

  2. Resources • Text: “Materials and the Environment”, Chapters 1 - 9 • Text: “Materials: engineering, science, processing and design”, 2nd Edition, Chapter 20 • Text: “Materials Selection in Mechanical Design”, 4th Edition, Chapter 16 • Software: CES EduPack with Eco-Audit tool • Poster: Wall chart of Eco-properties of materials Outline • Material consumption and life-cycle • LCA - problems and solutions • Eco-audits and the audit tool • Strategy for materials selection • Demo • Exercises

  3. 96% of all material Usage 20% of Global energy Material production Concern 1: Resource consumption, dependence

  4. 20% of all carbon to atmosphere Carbon to atmosphere Concern 2: Energy consumption, CO2 emission

  5. Life cycle assessment (LCA) Combust Landfill The product life-cycle Resources Emissions and waste

  6. Resource consumption Roll up into an “eco-indicator” ? Emissions inventory Impact assessment Life cycle assessment (LCA) Typical LCA output • Aluminum cans, per 1000 units • Bauxite 59 kg • Oil fuels 148 MJ • Electricity 1572 MJ • Energy in feedstock 512 MJ • Water use 1149 kg • Emissions: CO2 211kg • Emissions: CO 0.2 kg • Emissions: NOx 1.1 kg • Emissions: SOx 1.8 kg • Particulates 2.47 kg • Ozone depletion potential 0.2 X 10-9 • Global warming potential 1.1 X 10-9 • Acidification potential 0.8 X 10-9 • Human toxicity potential 0.3 X 10-9 ISO 14040 series PAS 2050 • Full LCA expensive, and requires great detail and skill – and even then is subject to uncertainty • How can a designer used these data?

  7. Alternative schemes Layout and materials CAD, FE analysis, optimization, costing Eco – audit ability Product specification Life cycle assessment Design guidance vs. product assessment Market need Problem statement Concept Embodiment Detail Production

  8. 16 14 12 10 8 6 4 2 0 -2 600 400 300 200 100 0 -100 Use Material Material Use Manufacture C02 equiv (kg) Energy (MJ) Manufacture Transport Transport EoL credit Disposal EoL credit Disposal This is the life-energy and life-CO2 (as prescribed in ISO 14040 and PAS 2050) These are potential benefits (could be recovered at end of life) Eco-audit for design Need: Fast Eco-audit with sufficient precision to guide decision-making • 1 resource – energy (oil equivalent)1 emission – CO2 equivalent • Distinguish life-phases

  9. Explore options with “What if..”s Analyse results, identify priorities Fast eco-audit 600 400 300 200 100 0 -100 600 400 300 200 100 0 -100 Use Initial design What if .. Different material? Material Use Material Energy (MJ) Energy (MJ) Manufacture Manufacture Transport Transport EoL credit EoL credit Disposal Disposal Eco-aware design: the strategy (1) The steps

  10. Look at the first three steps Explore options with “What if..”s Recommend actions & assess potential savings Analyse results, identify priorities Use CES to select new Materials and/or Processes Fast eco-audit Use eco-audit to indentify design objective 600 400 300 200 100 0 -100 Use Material Energy (MJ) Manufacture Transport EoL credit Disposal End of life Material Manufacture Transport Use Minimize: • material in part • embodied energy • CO2 / kg Minimize: • mass • distance • transport type Minimize: • mass • thermal loss • electrical loss Select: • non-toxic materials • recyclable materials Minimize: • process energy • CO2/kg Eco-aware design: the strategy (2) The steps

  11. Data from CES User inputs User interface • Bill of materials • Manufacturing process • Transport needs • Duty cycle • End of life choice Eco database • Embodied energies • Process energies • CO2 footprints • Unit transport energies • Recycling / combustion Eco audit model Outputs (including tabular data) The CES Eco-audit tool

  12. Typical record showing eco-properties

  13. ? ? ? ? ^ 1. Material, manufacture and end of life Add record Eco Audit Synthesizer Options…. How many? Name Choose material from CES DB tree Set recycle content 0 – 100% Enter mass Choose process Choose end-of-life path HELP at each step v 2. Transport v 4. Report v 3. Use The simple Audit tool: Levels 1, 2 and 3 1 Component 1 Cast iron 30% 2.4 Casting Recycle 1 Component 2 Polypropylene 0% 0.35 Molding Landfill

  14. Component name Material Process Mass (kg) End of life CES EduPack materials tree • Reuse • Refurbish • Recycle • Combust • Landfill • Casting • Forging / rolling • Extrusion • Wire drawing • Powder forming • Vapor methods Total process energy Total mass Total embodied energy Total end of life energy End of life options Available processes Material and process energy / CO2 Component 1 2.3 Recycle Aluminum alloys Casting Component 2 Polypropylene Polymer molding 1.85 Landfill Component 3 Glass Glass molding 3.7 Reuse

  15. Transport energy Transport CO2 Table of transport types: MJ / tonne.km CO2 / tonne.km Transport Transport stage Transport type Distance (km) Stage 1 350 32 tonne truck Stage 2 Sea freight 12000

  16. 1.2 kW Energy conversion path Fossil fuel to heat, enclosed system Fossil fuel to heat, vented system Fossil fuel to electric Fossil fuel to mechanical Electric to heat Electric to mechanical (electric motor) Electric to chemical (lead-acid battery) Electric to chemical (Lithium-ion battery) Electric to light (incandescent lamp Electric to light (LED) 365 0.5 W kW MW hp ft.lb/sec kCal/yr BTU/yr Total energy and CO2 for use Use phase – static mode Energy input and output Fossil fuel to electric Power rating Usage days per year hours per day Usage

  17. Number Name Material Process Mass (kg) End of life 100 Bottles PET Molding 0.04 Recycle 100 Caps Polyprop Molding 0.001 Recycle 100 Water 1.0 Transport Stage 1 14 tonne truck 550 km Use - refrigeration Fossil to electric 0.12 kW 2 days 24 hrs/day Bottled water (100 units) • 1 litre PET bottle with PP cap • Blow molded • Filled in France, transported 550 km to UK • Refrigerated for 2 days, then drunk

  18. 400 300 200 100 0 -100 -200 Energy (MJ) End of life Material Manufacture Transport Use 100% virgin PET with recycling 12 10 8 6 4 2 0 -2 -4 -6 Carbon (kg) End of life Material Manufacture Transport Use PET Glass ? 100% virgin PET with recycling The output: drink container The audit reveals the most energy and carbon intensive steps… … and allows rapid “What if…”

  19. Number Name Material Process Mass (kg) End of life 100 Bottles PET Molding 0.04 Recycle 0.45 Glass mold Soda glass 100 Caps Polyprop Molding 0.0001 Recycle 0.002 Rolling Aluminum 100 Water 1.0 Transport Stage 1 14 tonne truck 550 km Use - refrigeration Fossil to electric 0.12 kW 2 days 24 hrs/day Change the materials • 1 litre glass bottle with aluminum cap • Glass molded • Filled in France, transported 550 km to UK • Refrigerated for 2 days, then drunk

  20. Change of scale 800 600 400 200 0 -200 -400 400 300 200 100 0 -100 -200 Energy (MJ) Energy (MJ) End of life End of life Material Manufacture Transport Use Material Manufacture Transport Use 100% virgin PET with recycling 100% virgin glass with recycling 60 50 40 30 20 10 0 -10 -20 -30 12 10 8 6 4 2 0 -2 -4 -6 Change of scale Carbon (kg) Carbon (kg) End of life End of life Material Manufacture Transport Use Material Manufacture Transport Use 100% virgin PET with recycling 100% virgin glass with recycling Glass bottle replacing PET

  21. 400 300 200 100 0 -100 -200 400 300 200 100 0 -100 -200 Energy (MJ) Energy (MJ) End of life Material Manufacture Transport Use End of life Material Manufacture Transport Use 100% recycled PET with recycling 100% virgin PET with recycling 12 10 8 6 4 2 0 -2 -4 -6 12 10 8 6 4 2 0 -2 -4 -6 Carbon (kg) Carbon (kg) End of life End of life Material Manufacture Transport Use Material Manufacture Transport Use 100% recycled PET with recycling 100% virgin PET with recycling Use recycled PET instead of virgin?

  22. Is it practical to use recycled PET?

  23. 400 300 200 100 0 -100 -200 400 300 200 100 0 -100 -200 Energy (MJ) Energy (MJ) End of life End of life Material Manufacture Transport Use Material Manufacture Transport Use 100% virgin PET with recycling 100% virgin PET with combustion 12 10 8 6 4 2 0 -2 -4 -6 12 10 8 6 4 2 0 -2 -4 -6 Carbon (kg) Carbon (kg) End of life End of life Material Manufacture Transport Use Material Manufacture Transport Use 100% virgin PET with recycling 100% virgin PET with combustion Combust instead of recycle

  24. 1000 800 600 400 200 0 -200 -400 400 300 200 100 0 -100 -200 Change of scale Energy (MJ) Energy (MJ) Disposal Disposal Material Manufacture Transport Use Material Manufacture Transpt Use 100% virgin PET with air freight 100% virgin PET with truck transport 60 50 40 30 20 10 0 -10 -20 -30 12 10 8 6 4 2 0 -2 -4 -6 Change of scale Carbon (kg) Carbon (kg) Disposal Disposal Material Manufacture Transpt Use Material Manufacture Transport Use 100% virgin PET with air freight 100% virgin PET with truck transport Ship by air freight, refrigerate 10 days

  25. Pre-loaded in CES Edu 2011 • Bottled mineral water.prd • Hair dryer.prd • Electric kettle.prd • Portable space heater.prd • Family car.prd • Wind turbine.prd Students can explore change of • Material • Recycle content • Transport mode • Transport distance • Use pattern • Electric energy mix • End of life Teaching with the CES Eco-audit tool Introductory level teaching • Overview of the life cycle • Shown how Eco Audit Tool works • Pre-loaded projects Which life phase dominates? What could you do about it? • Self-made projects

  26. Bill of materials and processes 2 kW jug kettle • Made SE Asia • Air freight to UK • Life: 3 years Use Transport • 6 minutes per day • 300 days per year • 3 years • 12,000 km, air freight • 250 km 14 tonne truck Jug kettle

  27. What do we learn? • Little gained by change of material for its own sake • Much gained by insulation – double wall with foam or vacuum • Or make hot water on the fly – only as much as needed Eco audit: the jug kettle

  28. Same as the simple model ^ 1. Material, manufacture and end of life ? ? ? Add record Eco Audit Synthesizer Options…. Joining and finishing % recovered at end of life Machining, grinding, % removed v 2. Transport Choose joining (adhesives, fastners, welding) and finishing (painting, plating, powder coating) Set parameters ? v 3. Use v 4. Report The enhanced Audit tool: Eco Design 1 Component 1 Cast iron 30% 2.4 Casting Fine machining 10% Recycle 95% Component 1 Painting 0.55 m2 Component 1 Welding 0.7 m For advanced teaching the Enhanced Eco Audit Tool is available in the Eco Design Edition of CES EduPack

  29. So what? CES has two tools-sets to help explore the materials dimension of environmental design Tool 1. Eco-audits allows students to implement quick, approximate “portraits” of energy / CO2character of products. Tool 2. Selection strategies allows selection to re-design products to meet eco-criteria, using systematic methods They allow fast audits and systematic materials selection for redesign

  30. Lecture Unit Series These PowerPoint lecture-units are on the Teaching Resource Website Each frame of each unit has explanatory notes. You see them by opening the PowerPoint slide in Notes view (View – Notes pages) or by clicking this icon in the bottom toolbar of PowerPoint

  31. Also Available for Sustainability On the topics of: Eco Design & Eco Audits Low Carbon Power Systems • Exercises with Worked Solutions • Other Lecture Units • White Papers • Interactive selection case studies • Webinar recording • Poster • Sample Eco Audit Project Files • Links to other good resource sites • Eco Indicator Database http://teaching.grantadesign.com/open/eco.htm

  32. Author Reproduction Professor Mike Ashby University of Cambridge, Granta Design Ltd. www.grantadesign.com/education www.eng.cam.ac.uk This work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License. Please make sure that Mike Ashby and Granta Design are credited on any reproductions. You cannot use this resource for any commercial purpose. The Granta logo, the Teaching Resources logo and laptop image and the logo for the University of Cambridge are not covered by the creative commons license. http://creativecommons.org/licenses/by-nc-sa/3.0/ Accuracy We try hard to make sure these resources are of a high quality. If you have any suggestions for improvements, please contact us by email at teachingresources@grantadesign.com M. F. Ashby, 2011 Granta’s Teaching Resources Website aims to support teaching of materials-related courses in Engineering, Science and Design. The resources come in various formats and are primarily aimed at undergraduate students. This resource is one of 23 lecture units created by Professor Mike Ashby. The website also contains resources donated by faculty at the 800+ universities and colleges worldwide using Granta’s CES EduPack. The teaching resource website contains both resources that require the use of CES EduPack and those that don’t. Some of the resources, like this one, are open access. www.grantadesign.com/education/resources

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