GREEN BY DESIGN Pratt & Whitney’s Green Engine Program

1. GREEN BY DESIGNPratt & Whitney’s Green Engine Program Columbia University Industrial Ecology Course February, 2001 Pratt & Whitney Bob Tierney Pratt & Whitney - United Technologies Corporation

2. Today’s topics... • United Technologies Corporation • Pratt & Whitney’s Green Engine Program • Our conception of Life Cycle Assessment • Elimination of hazardous materials from life cycle • Strategic thoughts on implementing green

3. Progress !! Lead air emissions 98% decrease 1970-95 Lead in child’s blood 82% decrease 1976-95 CO emissions 30% decrease 1970-92 Auto hydrocarbons 98% decrease 1970-95 Lakes/ rivers 60% fully meet water stds. Bald eagle off endangered species list Sewage 100% treated in US (EU -72%) U.S. data unless noted

4. Progress ?? Electricity use per capita 21 % increase 1977-87 Aluminum consumption 1200% increase 1970-88 CO2 concentration 7% increase 1975-95 Waste to landfills 34% increase 1970-90 Ozone hole 60% deeper 1970-95 U.S. data unless noted

5. The Master Equation Global Envi. Impact Unit of Waste Unit of Resource Resource use Person = Population X X

6. Drivers for Green • State of the environment • Customers • Bottom line (Green = $$$$) • Top Line Growth • Wall St. • Politics/ Regulations • UTC Policy/ 10X Goals

7. Local Restrictions Increasing at an Accelerating Rate * * Based on 594 airports in Boeing database http://www.boeing.com/assocproducts/noise/list.html 2/22/00 25

8. Green Engine Program is structured as a matrix organization Design Suppliers Management Green Factory Technology Customer Requirements/ Communications

9. Pre-Manu facture Manu- Recovery Distribution facturing Management Life Cycle Assessment: The StagesFor the sake of simplicity the life cycle is divided into unit processes usually broken down as follows: pre-manufacture, manufacture, distribution and installation, use and service, and end of life management. Each unit process is then evaluated in three areas: safety, conservation, and pollution. The inputs and outputs of each life stage are the criteria for evaluation. Use & Service Reuse Remanufacture Revert

10. CO2 Emissions Factory vs. Use 55X

11. Develop Process Map with the “Goes-Ins” and the “Goes-Outs” Inputs Outputs Process or Activity Product or Service • Actions of People, • Equipment, Machines • Reactions of • Chemicals and Materials • Raw Materials • Chemicals • Energy • Fuels • Electricity By-products • Injuries • Illnesses • Inefficiencies • Air Emissions • Water Discharges • Solid/Liquid Waste

12. Machining & Metalworking 8% Degreasing 4% Painting 14% Misc.. Sources 32% Plating 5% Stripping 9% Cleaning & Rinsing 11% Surface Preparation & Treatment 17% Tap Into Existing Data Sources All Other Injuries Ergonomic Injuries 57% 43% Material Handling 37% Maintenance & Service 11% Manufacturing & Assembly 26% Injuries by type and operation Hazardous waste sent off site by process source

13. Is it Good, Bad or Ugly?

14. Elements of a Green Engine Vision: Pratt & Whitney sets the Standard for Green Has the lowest possible Emission Impact during use Has lowest possible Noise Impact Is manufactured and serviced using Green Processes Is designed with Human Factors in mind Is Material Efficient (Metal Buy-to-fly, Propellant Yield ) Is Energy Efficient during use (Fuel Burn) Contains Green Materials Has least possible Factory Impacts Involves Green Suppliers and Partners Is Designed for Serviceability, Reusability, Recyclability

15. Understanding Impacts is Key to Continuous Improvement Job Ticket/ SRD/ CRD LCA Goals Design Standard Work Design Specifications Procurement Process Operating Procedures End of Life Service Use Distribute P&W Manufacturing Supplier Manufacturing Environment, Safety, Natural Resources Impact

16. Knowing Where to Apply the ‘Green’ Pressure Points Customer Req’mt Team Technology Team Supplier Team Job Ticket/ SRD/ CRD LCA Goals Design Standard Work Design Specifications Procurement Process Design Team Green Factory Team Operating Procedures End of Life Service Use Distribute P&W Manufacturing Supplier Manufacturing Environment, Safety, Natural Resources Impact

17. SUPPORT PLANNING DEFINITION VALIDATION DELIVERY LCA as Part of Integrated Program Deployment (IPD) PRODUCT LIFE CYCLE ASSESSMENT TECHNICAL SUPPORT Product Requirements Market Feedback Analysis EH&S ANNUAL PLANNING& EVALUATION Aspects & Impacts Objectives & Targets

18. Baseline LCAs are the Standard by Which Future Products Are Compared Large Gas Turbine Engine General Aviation Engine Liquid Rocket (expendable & serviceable) Solid Rocket (expendable & serviceable)

19. What is a Life Cycle Assessment? • Qualitative process used to assess EH&S • impacts of product during its lifecycle • What does it provide? • Relative magnitude of EH&S impacts • Areas of information gaps • Priorities for green design • Priorities for green technology development • And…. • Raises consciousness of organization

20. Materials/ Processes of Concern

21. MATERIALS OF CONCERN FOR GAS TURBINE AND ROCKET PROPULSION SYSTEMS • Materials Of Concern • Hazardous Materials Index • Product Comparisons • Standard Work • Green Technology Goals • Summary

22. Materials Of Concern Objectives • Identify hazardous material risks across the enterprise • Provide a deliverable for incorporation into standard work • Create a green index to drive green technology plan Rationale • Appearance of targeted materials on one or more industry, customer or regulatory list(s) of hazardous materials • Relevance to Pratt & Whitney product lines or processes • Potential linkage to product and process design callouts

23. Definition Of Categories • Prohibited • high risk materials not permitted in new design and development • Restricted • high risk materials that can only be used with appropriate levels of approval • plan must be established to validate alternate green material • To Be Reduced • materials known to have detrimental environmental, health and safety impacts.

24. Materials of Concern Prohibited Restricted To Be Reduced Arsenic & compounds Asbestos Benzene Beryllium Cadmium & compounds Chlorinated solvents Ethyl alcohol Ethylene glycol ether compounds Formaldehyde Mercury & compounds Methanol (methyl alcohol) Methylene chloride Class I ozone depleting substances Radioactive materials, including Thoriated (TD) nickel Toluene diisocyanate Chromium, hexavalent Class II ODS Cyanides Dimethylformamide HCFC-14 lb & HCFC-22 Hydrazine Hydrofluoric acid Hydrogen fluoride gas Lead & compounds Manmade fibers, e.g., cristobalite, fiberfrax MDA (4’, 4’-Methylenedianiline) Methyl alcohol (methanol) Methyl ethyl ketone (MEK, 2-butanone) Methyl iso-butyl ketone (MIBK, 4-methyl-2-pentanone) Phenol Styrene Toluene Xylene Acetone Ammonia Butyl alcohol Ethyl benzene n-Hexane Hydrochloric acid Isocyanates n-methyl-2-pyrrolidone Isopropyl alcohol Nickel plate Nitric acid Petroleum distillates (e.g., naptha, mineral spirits, stoddard solvent, varsol, evaporative lubricants) Phosphoric acid Sec-butyl alcohol Sulfuric acid 1, 2, 4-Trimethylbenzene

25. Hazardous Materials Index • Purpose • provide metric to define “greenness” of products • link materials to specifications/design callouts • Assign “toxicity” values to materials & process specifications based on Purdue University rankings • Quantify green indices based on Pratt & Whitney Canada algorithm: Ih = T*nP/N where: Ih = Hazardous Material Index T = toxicity value of specification nP = number of part numbers that call out specification N = total number of part numbers in engine

26. Hazardous Materials Index Implementation • Establish metrics/set goals • Establish signoff/approval protocols • Control via standard work

27. Technology Opportunity

28. Standard WorkMaterials Of Concern • Contains background, contacts and protocols • References material and process specification list • Links to data base containing materials of concern, toxicity rating detail, identified by specifications • Links to menu for selection of alternate materials and processes, cross-referenced by specification

29. Materials of Concern List with Specification Number

30. Green Technology Goals • Goals established based on driving down product hazardous materials index • Goal for legacy products will be based on designing out prohibited materials • Goal for new designs will be based on eliminating the use of restricted materials

31. Summary • Comprehensive effort to identify hazardous material risks across the Pratt & Whitney enterprise • Risks defined by levels of concern • Standard work tool for designers established • Goals in process of being defined • Hazardous Materials Index will drive technology

32. Rod Elkington, Chairman: “Tomorrow’s economy will be about increasing returns where we learn to exploit virtuous cycles rather than manage vicious ones.”