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IE 5331 Sustainable Engineering2012 fall

Texas Tech University

Department of Industrial Engineering

August 30, 2012

Chapter 1: Essential Concept and Technology for Future Engineering

Zhang, Hong-Chao

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Glass or plastic bottle which one is better for environment?

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� Chapter 1: Introduction to LCA

� Chapter 2: Goal Definition and Scoping

� Chapter 3: Life Cycle Inventory

� Chapter 4: Life Cycle Impact Assessment

� Chapter 5: Interpretation

� Chapter 6: Economic Input-Output Analysis

� Chapter 7: Case Studies

� Chapter 8: New Trends

� Course Project

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Sustainable Engineering Course Outline

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Sustainable Engineering Questions

� Sustainable engineering is

� an emerging and popular topic in today’s engineering education practices.

� As a future engineer, do you understand what is sustainable engineering?

� What is low carbon manufacturing?

� What methodologies and tools are used in today’s industry practices for sustainability?

� What are the future trends in this area?

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� Objectives---This course will provide the basis for understanding: � (1) what is envisioned as sustainable manufacturing and

how that associates to larger issues of global warming, energy independence, and social impact;

� (2) what comprises sustainable manufacturing practices in for-profit enterprises;

� (3) how to practice and measure continuous improvement using sustainability thinking;

� (4) techniques and tools for product and manufacturing process design and development;

� (5) effective communication of sustainability performance to internal and external audiences.

Sustainable Engineering Introduction-1

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� A popular used analytical method

� life cycle assessment (LCA), will be taught in details. Students will learn the LCA method to evaluate different products and their environmental impacts by means of total life cycle assessment.

� Real world industrial case studies will be introduced in this course.

Sustainable Engineering Introduction-1

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� Prerequisite:� Consent of Instructor. Fundamental knowledge and

application theory for total Life Cycle Assessment (LCA) for products and manufacturing processes;

� Analytical methods and application tools which are highly demanded by modern manufacturing enterprises are introduced.

� Three-dimensional sustainability, i.e. environmental, social, and economical are especially addresses by means of industrial case studies.

� Text book: No

Sustainable Engineering Course Description

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Sustainable Engineering Course Description

�Reference Book:

Henrik Wenzel, et al. “Environmental

Assessment of Product,” vol. 1 & 2,

Chapman & Hall, 1997.

�Reference Website:

www.epa.gov

search for: EPA ---Life Cycle

Assessment Principles and practice

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Sustainable Engineering Course Description

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� Cover page of LCA Doc

� www.epa.gov/nrmrl/lcaccess/pdfs/600r06060.pdf

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� Hong C. Zhang, Professor:

� Department of Industrial Engineering

� E-mail: hong-chao.zhang@ttu.edu

� Phone: 742-4853

Sustainable Engineering Coordinator

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� This course will provide the basis for understanding:

� (1) what is envisioned as sustainable manufacturing and how that associates to larger issues of global warming, energy independence, and social impact;

� (2) what comprises sustainable manufacturing practices in for-profit enterprises;

� (3) how to practice and measure continuous improvement using sustainability thinking;

� (4) techniques and tools for product and manufacturing process design and development;

� (5) effective communication of sustainability performance to internal and external audiences.

� Upon completion of this course graduate students should be able to learn the mostly quantitative and qualitative methods, tools, and methodologies that widely used in today’s modern manufacturing practice.

Sustainable Engineering Educational Objectives:

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� This course will provide students with three broad skills :

� (1) Ability to select and utilize the appropriate quantitative and qualitative concepts, tools, and methodologies, to accomplish a real world case of total product life cycle assessment;

� (2) Ability to initiate, continue, summarize, and successfully present the real world project work by means of technical reporting, oral and visual poster presentation;

� (3) Ability to collaborate with team members and handle and enhance team work in a similarly real manufacturing environment;

Sustainable Engineering Course Outcomes:

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Sustainable Engineering Course Schedule:

Topic Date

Part IIntroduction and Life Cycle AssessmentGoal Definition and Scoping

8/28 – 9/11

Part IILife Cycle Inventory

9/13 – 9/27

Part III Life Cycle Impact Assessment

10/02 – 10/23

Part IVLife Cycle InterpretationEconomic Input-Output Analysis

10/25 – 11/06

Part VIndustrial Case StudyLife Cycle Assessment ― New Trends

11/08 – 11/15

Part VIFinal presentation 11/27 – 12/04

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Sustainable Engineering Grading Polity:

Grading Polity:

Homework 20%

Project (including presentation) 50%

Test 30%

� Letter grades will be based on a 90-80-70-60 scale.

� All tests are close-book and close-note unless otherwise stated. Homework and the project will be collected at the beginning of each class. Delay in submission will cause deduction of the scores.

� The Professor reserves the right to assign the final grade for the course. Condition to obtain a higher or lower grade will depend upon 1) class participation, 2) attendance to class, and 3) improved or declining performance on graded work.

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Sustainable Engineering General Policies:

� 1. NO cellular phones, iPods (or any other MP3 player), and/or laptops are allowed during the duration of the class period.

� 2. NO food is permitted during the lectures (beverage ARE allowed to be consumed).

� 3. Class discussion is encouraged

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� Any student who, because of a disability, may require special arrangements in order to meet the course requirements should contact the professor as soon as possible to make any necessary arrangements.

� Students should present appropriate verification from Student Disability Services during the professor’s office hours. Please note professors are not allowed to provide classroom accommodations to a student until appropriate verification from Student Disability Services has been provided.

� For additional information, you may contact the Student Disability Services office at 335 West Hall or 806-742-2405.

Sustainable Engineering Special Needs:

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We are lighting up the earth?!

17Credit:Data courtesy Marc Imhoff of NASA GSFC and Christopher Elvidge of NOAA NGDC. Image by Craig Mayhew and Robert Simmon, NASA GSFC.

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Sustainable EngineeringTopic

We do not inherit the Earth from We do not inherit the Earth from We do not inherit the Earth from We do not inherit the Earth from We do not inherit the Earth from We do not inherit the Earth from We do not inherit the Earth from We do not inherit the Earth from

our parents; we borrow it from our parents; we borrow it from our parents; we borrow it from our parents; we borrow it from our parents; we borrow it from our parents; we borrow it from our parents; we borrow it from our parents; we borrow it from

our children.our children.our children.our children.our children.our children.our children.our children.

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Sustainable EngineeringBurden on the Environment� National Safety Council Statistics:

� By 2004, only 16% of computers were recycled.

� There will be 500 million obsolete computers in US by 2007. The figure will continue to increase.

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Sustainable Engineering Burden on the Environment� 500 million computers is equivalent to

� A typical computer = 16 inches in length

� One Mile = 5280ft

� Total Distance = 126,263 miles

� Earth’s equator =24,900miles

� Circle the earth 5.1 times

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� Extension of Life Cycle Concept

Sustainable Engineering Life Cycle Concept

Product Design

Product

Process

Logistic Support

Manufacturing DisposalUtilization

Production & recycling design

Production design & production support

Production Process

RecyclingProcess

Support & Maintenance

RecyclingSupport

Reuse

Remanufacturing

Application phase

Utilizationphase

Recycling phase

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Sustainable Engineering Definition � “Sustainable manufacturing is defined as the

creation of manufactured products that use processes that minimize negative environmental impacts, conserve energy and natural resources, are safe for employees, communities, and consumers and are economically sound.”

— U.S. Department of Commerce Definition

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IE 5331: Sustainable Engineering Introduction � Sustainable Development (SD)

� A principle that economic development should meet the needs of the present without compromising the ability of future generations to meet their own needs. The essence is to recycle, reuse, and reduce material service and protect global environment

� Industrial Ecology (IE)� A strategy or practical approach to sustainability.

The decision making of industrial production should take the operation of the ecosystem as a model to formulate a close loop for substances and materials. The principle of Industrial Ecology is to construct mass conservation.

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Sustainable Engineering Sustainable Manufacturing

� Sustainable Manufacturing

� Apply SD and IE to manufacturing to reengineer product design, manufacturing processes and system development to efficiently utilize energy, raw materials, and reactant to minimize the pollutants and to support the sustainable development of the mankind.

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Introduction to Life Cycle AssessmentOUTLINE

� Definition of LCA� Components in LCIA

� Goal Definition and Scoping� Inventory Analysis:� Impact Assessment� Interpretation

� Benefits and Limitations of LCA� History of LCA� Conclusion

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Introduction to Life Cycle AssessmentWhat is LCA? -1� As environmental awareness increases,

industries and businesses are assessing how

their activities affect the environment. Society

has become concerned about the issues of

natural resource depletion and environmental

degradation.

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Introduction to Life Cycle AssessmentWhat is LCA? -2� Many businesses have responded to this

awareness by providing “greener” products and

using “greener” processes.

� The environmental performance of products and

processes has become a key issue, which is why

some companies are investigating ways to

minimize their effects on the environment.

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Introduction to Life Cycle AssessmentWhat is LCA? -3

� Many companies have found it advantageous to

explore ways of moving beyond compliance

using pollution prevention strategies and

environmental management systems to improve

their environmental performance.

� One such tool is LCA. This concept considers the

entire life cycle of a product.

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Introduction to Life Cycle AssessmentWhat is LCA? -4� Life cycle assessment is a “cradle-to-grave”

approach for assessing industrial systems.

� “cradle to cradle” ------� begins ---- gathering of raw material from earth� ends ---- all material are returned to earth

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Introduction to Life Cycle AssessmentWhy is LCA? -1

� LCA evaluates all stages of a product’s life from

the perspective that they are interdependent,

meaning that one operation leads to the next.

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Introduction to Life Cycle AssessmentWhy is LCA? -2

� LCA enables the estimation of the cumulative environmental impacts resulting from all stages in the product life cycle.

� Often including impacts not considered in more traditional analyses (e.g., raw material extraction, material transportation, ultimate product disposal, etc.).

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Introduction to Life Cycle AssessmentWhy is LCA? -3� By including the impacts throughout the product

life cycle, LCA provides:

� A comprehensive view of the environmental aspects of the product or process

� A more accurate picture of the true environmental trade-offs in product and process selection.

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Introduction to Life Cycle AssessmentWhy is LCA? -4

� The term “life cycle” refers to the major activities in the course of the product’s life-span:

� From its manufacture, use, and maintenance, to its final disposal;

� Including the raw material acquisition required to manufacture the product;

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Introduction to Life Cycle AssessmentWhy is LCA? -5

Raw Material

Energy

Atmospheric Emission

Inputs Outputs

Waterborne Wastes

Solid Wastes

Coproducts

Other Releases

Raw Materials Acquisition

Manufacturing

Use / Reuse / Maintenance

Recycle / Waste Management

� Life Cycle Stages

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Introduction to Life Cycle AssessmentWhy is LCA? -6� Specifically, LCA is a technique to assess the

environmental aspects and potential impacts associated with a product, process, or service, by:

� Compiling an inventory of relevant energy and material inputs and environmental releases

� Evaluating the potential environmental impacts associated with identified inputs and releases

� Interpreting the results to help decision-makers make a more informed decision.

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Introduction to Life Cycle AssessmentLCA Phases -1

Goal Definition and Scope

Inventory Analysis

Impact Assessment

Interpretation

Life Cycle Assessment Framework

Define and describe the product, process or activity. Establish the context in which the assessment is to be made and identify the boundaries and environmental effects to be reviewed for the assessment

Identify and quantify energy, water and materials usage and environmental releases (e.g., air emissions, solid waste disposal, waste water discharges).

Assess the potential human and ecological effects of energy, water, and material usage and the environmental releases identified in the inventory analysis

Evaluate the results of the inventory analysis and impact assessment to select the preferred product, process or service with a clear understanding of the uncertainty and the assumptions used to generate the results.

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Introduction to Life Cycle Assessment LCA Phases -2� Life cycle assessment is unique because it

encompasses all processes and environmental releases beginning with the extraction of raw materials and the production of energy used to create the product through the use and final disposition of the product.

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Introduction to Life Cycle Assessment Benefits of LCA -1

� An LCA can help decision-makers select the product or process that results in the least impact to the environment.

� This information can be used with other factors, such as cost and performance data to select a product or process.

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Introduction to Life Cycle Assessment Benefits of LCA -2

� LCA data identifies the transfer of environmental impacts:

� From one media to another (e.g., eliminating air emissions by creating a wastewater effluent instead)

� And/or from one life cycle stage to another (e.g., from use and reuse of the product to the raw material acquisition phase).

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Introduction to Life Cycle Assessment Benefits of LCA -3

� If an LCA were not performed, the transfer might not be recognized and properly included in the analysis because it is outside of the typical scope or focus of product selection processes.

� LCA Helps to Avoid Shifting Environmental Problems from One Place to Another

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Introduction to Life Cycle Assessment Benefits of LCA -4� This ability to track and document shifts in

environmental impacts can help decision makers and managers fully characterize the environmental trade-offs associated with product or process alternatives.

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Introduction to Life Cycle Assessment Benefits of LCA -5� By performing an LCA, analysts can:

� Develop a systematic evaluation of the environmental consequences associated with a given product.

� Analyze the environmental trade-offs associated with one or more specific products/processes to help stakeholder (state, community, etc.) acceptance for a planned action.

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Introduction to Life Cycle Assessment Benefits of LCA -6

� Quantify environmental releases to air, water, and land in relation to each life cycle stage and/or major contributing process.

� Assist in identifying significant shifts in environmental impacts between life cycle stages and environmental media.

� Assess the human and ecological effects of material consumption and environmental releases to the local community, region, and world.

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Introduction to Life Cycle Assessment Benefits of LCA -7

� Compare the health and ecological impacts between two or more rival products/processes or identify the impacts of a specific product or process.

� Identify impacts to one or more specific environmental areas of concern.

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Introduction to Life Cycle Assessment Limitations of LCA -1

� Performing an LCA can be resource and time intensive.

� Depending upon how thorough an LCA the user wishes to conduct, gathering the data can be problematic, and the availability of data can greatly impact the accuracy of the final results.

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Introduction to Life Cycle Assessment Limitations of LCA -2

� Therefore, it is important to weigh:

� The availability of data,

� The time necessary to conduct the study

� The financial resources required against the projected benefits of the LCA.

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Introduction to Life Cycle Assessment Limitations of LCA -2

� LCA will not determine which product or process is the most cost effective or works the best.

� Therefore, the information developed in an LCA study should be used as one component of a more comprehensive decision process assessing the trade-offs with cost and performance, e.g., Life Cycle Management.

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� Early roots in the sixties in USA� energy analysis� packaging

� Silent seventies

� Awakening interest in the eighties� packaging again - this time in Europe� product stewardship from cradle to grave

(sustainability)� internationally co-ordinated method development

Introduction to Life Cycle Assessment History of LCA -1

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� Consolidation during the nineties� growing product focus in industry and authorities� many new applications and practitioners� international standardisation (ISO)

� Globalisation in the new millennium� the UNEP/SETAC life cycle initiative

Introduction to Life Cycle Assessment History of LCA -2

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Introduction to Life Cycle Assessment General Conclusion �Purpose of LCA:

�Identify potential environmental tradeoffs

�Benefits:

�Help decision-makers compare all major

environmental impacts

�Limitations:

�Availability of data

�Time cost to conduct this study

�Financial resources required against the benefits

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Sustainable Engineering Sustainable Manufacturing

� Two Parts of Homework for today 04/13/2010

� Part I:

� Form your project group with total 5 students. Please send all four students names to: sustain_homework@163.com

� in either English or Chinese. Please use asterisk “*” to denote who is the coordinator.

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Sustainable Engineering Sustainable Manufacturing

� Homework for today, due on 09/06/2012

� What do you expect to learn from this course?

� Please discuss in details what is WEEE directive?

� Please discuss in details what is RoHSdirective?

� Please discuss in details what is ERP directive?

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IE 5331: Sustainable Engineering