Transcript Environmentally Conscious Design & Manufacturing ME592E-1

Environmentally Conscious
Design & Manufacturing
Class 2: Industrial Ecology
& Manufacturing
Prof. S. M. Pandit
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
Slide:1
Industrial Ecology and Manufacturing Case Study:
The Automobile - A Discrete Manufactured Product
Agenda
 Environmental Impact “The Master Equation”
 Automobile sub-systems & Environmental Impact
 Environmental interactions during manufacturing
 Energy consumption & Motive energy options
 Infrastructure: Embedded energy in roads
 Environmental interactions during product use
References:
Graedel & Allenby “Industrial Ecology and the automobile”
EPA
Web
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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The Master Equation
Quantitative estimates of the environmental impact in a
particular locality (or eco - system)
Population
Gross
Domestic
Product
Env. impact
per unit of
GDP
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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The Master Equation
E = [P] [ip 
P = P0 exp {Rt}
E = Environmental Impact
P = Population (temporal)
ip= Gross Domestic Product(GDP) / person
 = Environmental Impact / GDP
Po = Initial population
t = Time
R = Net rate of growth = (Rb - Rd) + (Ri - Re)
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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The Master Equation
E

Pip
Time
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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The Master Equation
As we move towards sustainable manufacturing,
The environmental
impact surface
should become
flatter.
d/dt [Pollutant generation]
< d/dt [Pollutant processing]
Short / Long term implications
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Automobile Sub-systems &
Environmental Impact
Societal & Cultural Factors
Constituents
Environmental impact
Design
Questions Addressed
Sub-systems ?
Impact of design and materials - Technology focus
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Date: March 8, 2000
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Automobile Sub-systems &
Environmental Impact
Mechanics,
Thermofluids
Overview of
Sub-Systems
Tribology
Chemical processing,
Thermofluids
Machines,
Signal processing
Chassis
Frame
Engine
Brakes
Cooling systems
Lubrication
Tires
Fuel
Paint
Emission Control
Electrical power
Electronics
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Automobile Sub-systems &
Environmental Impact
Materials selected (how do we look at properties?) :
Ferrous
Cast Irons
Time - Temperature
dependent diffusion
Steel
of C in Fe
Alloy steels
Aluminum alloys
Ceramics
Composites
Polymers
Fluids
Engine / Transmission /
Ref: http://ate.cc.vt.edu/eng/materials/classes
Brake / Battery
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Automobile Sub-systems &
Environmental Impact
Environmental
Impact
• Raw Material depletion
• Combustion by-products
• Manufacturing Process Waste Streams
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Automobile Sub-systems &
Environmental Impact
Design factors and Environmental Impact
•
•
•
•
•
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•
Combustion Efficiency
Weight
Corrosion resistance
Ease of Manufacturing
Functionality
Cost
Recyclability
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Environmental Interactions during
Manufacturing
Upstream Input(s)
Raw
Materials
&
Energy
Manufacturing
process
Waste
Streams
Downstream Output(s)
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Environmental Interactions during
Manufacturing
Typical Manufacturing Processes, inputs and outputs
• What can we do with these?
Develop analytical I/O models
- Based on experimental data (Regression,DDS)
- Based on a physical understanding of the process
(still using models developed to describe basic
interactions; e.g. rate phenomenon in chemical
metallurgy to describe chemistry change and
effluents in welding processes)
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Environmental Interactions during
Manufacturing
Aromatic hydrocarbons
released from binder.
&
Heat released
Casting & Forming:
- Sand discarded after use
Other Processes: Die Casting, Injection molding,
Welding and Brazing, Metal Plating, Painting
Environmentally Conscious Design & Manufacturing (ME592)
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Environmental interactions during
manufacturing
“Greening” the manufacturing processes (How)
- Energy management
- Better mold utilization
- Reuse of contaminated water
- Waste water treatment options
- TRANSITION TO NEW PROCESSES?
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Energy Consumption (urban use)
Other losses
Standby (3.6%) Accessories (1.5%)
Aero: 10.9%
Rolling: 7.1%
Braking: 2.2%
Engine
Engine Losses (69.2%)Driveline losses (5.4%)
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Energy Consumption (options)
C - Based Fuels
CH3OH
Nat. Gas
C2H5OH
High Cost, Smog, Global Warm
High Cost, Smog, Global Warm
High Cost, Smog, Bio.
Corn-based: 5% of needs
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Energy Consumption (options)
Electric Vehicles: - Electro-Chemical Batteries
- Electromechanical Batteries
Hybrid power
Fuel Cells
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Energy Consumption (options)
Hybrid:
Fuel economy of 66 mpg and emission
reductions of 50% for carbon dioxide and
90% for carbon monoxide, hydrocarbons
and nitrogen oxide
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Energy Consumption (options)
About Fuel Cells
Ref: http://www.benwiens.com/energy1.html
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Infrastructure: Embedded Energy in Roads
Material
Energy(J/kg)
Embedded
Bitumen
0.63
Cement
6.70
Aggregate
0.07
Reinforcing steel 23
Steel Beams
18
Environmentally Conscious Design & Manufacturing (ME592)
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Infrastructure: Embedded Energy in Roads
Energy / km of urban roads
8.4 x 1012J
Total Embedded Energy:
(x1018J)
Roads:
Bridges:
190
1.5
Estimated worldwide
“embedded energy”
in roads
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Environmental Interactions
during Product Use
Auto use residues or potential waste streams
{Principal Environmental Impact occurs during use, and
this is therefore the most “significant” life cycle stage}
• Solids
• Liquids
• Gaseous
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Environmental Interactions
during Product Use
Liquids:
Solids:
Oil
Batteries (10% lead loss)
Antifreeze
Tires (freeze and grind?)
Scrap - How do you quantify? Battery Acids
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Environmental Interactions
during Product Use
Gaseous Emissions:
In many urban areas, motor vehicles are the single
largest contributor to ground-level ozone, a major
component of smog. Ground-level ozone is the
most serious air pollution problem in the northeast
and mid-Atlantic states. - EPA
http://www.dieselnet.com/standards/cycles
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Date: March 8, 2000
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Environmental Interactions
during Product Use
Cars also emit several pollutants classified as toxics,
which cause as many as 1,500 cases of cancer in the
country each year. Auto emissions also contribute to
the environmental problems of acid rain and global
warning. - EPA
Ref: http://www.nsc.org/ehc/mobile/mse_fs.htm
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Environmental Interactions
during Product Use
CxHy:
Hydrocarbons react with nitrogen oxides in the
presence of sunlight and elevated temperatures
to form ground-level ozone.
It can cause eye irritation, coughing, wheezing,
and shortness of breath and can lead to
permanent lung damage.
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Environmental Interactions
during Product Use
NOx
Nitrogen oxides also contribute to the formation of
ozone and contribute to the formation of acid rain
and to waterquality problems.
CO
Carbon monoxide is a colorless, odorless, deadly
gas. It reduces the flow of oxygen in the
bloodstream and can impair mental functions and
visual perception. In urban areas, motor vehicles are
responsible for as much as 90 percent of carbon
monoxide in the air.
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Date: March 8, 2000
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Environmental Interactions
during Product Use
Clean - up
the toxins (How?)
•Chemical Catalysis
•Absorption
•Adsorption
How about biodegradation?
http://news.pollutiononline.com/common
Environmentally Conscious Design & Manufacturing (ME592)
Date: March 8, 2000
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Environmental Interactions
during Product Use
Where From?
• When outside temperatures on hot, sunny days
cause a car's fuel to evaporate
• Hot engine and exhaust system of a running car
cause the fuel to become heated
• When the car is shut off and remains hot enough
to cause fuel to evaporate
• During refueling, when gasoline vapors escape
into the air from the gas tank and the nozzle
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Date: March 8, 2000
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