Work with Performance Equation to Optimize your Score!

1. Work with Performance Equation to Optimize your Score! • Weight • Structural analysis, failure analysis, load impact when lift starts (Use Excel) • Height • Structure geometry, pulley placement (Use Solid Works, ACAD, Excel) • Time • Ask Dr. Head! • Cost • Mass and $/unit mass aluminum and plastic, energy cost (Use Excel) • LCA • Mass aluminum and plastic, disposal methods (ECO-it)

2. Life Cycle Assessment Sophomore Clinic Fall 2003 (With thanks to Dr. Jansson and Hesketh)

3. Overview • Why care about the environment? • Environmental Problems • Basic Environmental Design • Life Cycle Assessment • Hoistinator • Eco-IT

4. Intergenerational Responsibility The Earth belongs…to the living…No man can by natural right oblige the lands he occupied, or the persons who succeeded him in that occupation, to the payment of debts contracted by him. For if he could, he might, during his own life, eat up the usufruct [products] of the lands for several generations to come, and then the lands would belong to the dead and not the living. -Thomas Jefferson, in a letter to James Madison, 1789

5. Why Should Engineers Care about the Environment? • Regulations • Money • Ethics

6. Engineers and Environmental Regulations Major Laws/Amendments Environmental Regulations Bishop, “Pollution Prevention: Fundamentals and Practice”, McGraw-Hill, 2000 -Robert Hesketh

7. Money • Cost of clean up • 2,000 to 4,500 contaminated sites • $100 to $165 Billion • ~$2 Billion / year • Cost avoidance • Lower material / energy costs • Lower waste disposal costs

8. Global Warming and Related Impacts Materials Energy Cause and Effect Chain Products Process of Concern greenhouse gas emissions CO2, CH4, N2O climate change; sea level change human mortality or life adjustments Contribution to global Warming; Phipps, NPPC, http://www.snre.umich.edu/nppc/ Climate Change 1995, Intergovernmental Panel on Climate Change, WMO and UNEP, Cambridge University Press, 1996. -Robert Hesketh

9. Stratospheric Ozone and Related Impacts Cause and Effect Chain Materials Energy Products Process of Concern ozone depleting substances CFCs, HCFCs human mortality or life adjustments ecosystem damage ozone layer loss increase in uv Toxics Release Inventory Data Climate Change 1995, Intergovernmental Panel on Climate Change, WMO and UNEP, Cambridge University Press, 1996. -Robert Hesketh

10. Smog formation and related impacts Cause and Effect Chain Materials Energy Products Process of Concern human/ecological damage from O3 and other oxidants NOx and volatile organic substances photochemical oxidation reactions 1 - Chemical & Allied Processing 2 - Petroleum & Related Industries NOx VOCs NOx 1997 Miscellaneous 3 - Metals Processing, 4 - Other Industrial Processes 5 - Solvent Utilization, 6 - Storage & Transportation 7 - Waste Disposal & Recycling Transportation Industrial Processes VOCs 1997 Fuel Combustion National Air Quality and Emissions Trends Report, 1997, U.S. EPA Office of Air Quality Planning and Standards, http://www.epa.gov/oar/aqtrnd97/chapter2.pdf -Robert Hesketh

11. Acid rain / Acid deposition Cause and Effect Chain Materials Energy Products Process of Concern human/ecological damage from H+ and heavy metals SO2 and NOx emission to air Acidification rxns. & acid deposition SO2 1997 Miscellaneous 1 - Chemical & Allied Processing 2 - Petroleum & Related Industries 3 - Metals Processing 4 - Other Industrial Processes 5 - Solvent Utilization 6 - Storage & Transportation 7 - Waste Disposal & Recycling Transportation Industrial Processes Fuel Combustion National Air Quality and Emissions Trends Report, 1997, U.S. EPA Office of Air Quality Planning and Standards, http://www.epa.gov/oar/aqtrnd97/chapter2.pdf -Robert Hesketh

12. Human Health Toxicity Materials Energy Products Process of Concern Transport, fate, exposure pathways & routes Human health damage; carcino- genic & non... Toxic releases to air, water, and soil EPCRA Toxic Waste RCRA Hazardous Waste Allen and Rosselot, 1997 -Robert Hesketh

13. Eco-Effectiveness and Design • Get Free of Known Culprits • Avoid chemicals that are known problems • E.g., cadmium, lead, mercury • Follow Informed Personal Preferences • When dealing with gray areas, data uncertainty,… • Create Lists • X list (Known Culprits): Avoid • Gray List: Problematic, but may be best, or only, available • Positive list: Preferred • Reinvent Good Better Best Cradle to Cradle, by McDonough & Braungart, 2002

14. How? • How can we reinvent? How can we determine which designs are more Eco-effective? • Life-Cycle Assessment can help • Evaluating environmental impacts over a product’s entire life cycle

15. Product Life Cycle Materials Materials Materials Materials Life- Cycle Stages Energy Energy Energy Energy Raw Materials Extraction Material Processing Product Manufacturing Use, Reuse, Disposal Impacts Impacts Impacts Impacts Life- Cycle Impacts other toxic releases resource depletion Human health and ecosystem damage global warming ozone depletion smog formation acidifi- cation - Adopted from Robert Hesketh

16. Product Life Cycle Materials Materials Materials Materials Life- Cycle Stages Energy Energy Energy Energy Raw Materials Extraction Material Processing Product Manufacturing Use, Reuse, Disposal Impacts Impacts Impacts Impacts Life- Cycle Impacts other toxic releases resource depletion Human health and ecosystem damage global warming ozone depletion smog formation acidifi- cation - Adopted from Robert Hesketh

17. Product Life Cycle Materials Materials Materials Materials Life- Cycle Stages Energy Energy Energy Energy Raw Materials Extraction Material Processing Product Manufacturing Use, Reuse, Disposal Impacts Impacts Impacts Impacts Life- Cycle Impacts other toxic releases resource depletion Human health and ecosystem damage global warming ozone depletion smog formation acidifi- cation - Adopted from Robert Hesketh

18. Product Life Cycle: Aluminum and Plastic Members • Raw Material Extraction • Extract bauxite and petroleum • Material Processing • Make aluminum from bauxite and resin beads from petroleum • Product Manufacture • Make bar stock out of aluminum and plastic • Make structural members from bar stock • Assemble • Disposal • Both Aluminum and Plastic are recyclable • Plastic can be burned for energy recovery • Both can be landfilled IMPACTS: Green House Gasses, Ozone Depletion, Energy Use, Natural Resource Depletion, Landfill Space, Energy Recovery…

19. What is LCA? • A life cycle assessment is an environmental analysis of a product that includes: • Goal • Scope • Inventory • Impact assessment • Defines and quantifies service provided by product, quantifies environmental exchanges, and ascribes potential impacts • Standards - ISO 14040

20. The LCA Process Impact Assessment Goal Scope Inventory Assess product Improve product Compare products Design new product Create product specifications Functional Unit Reference product(s) Assessment parameters Important Processes Time Horizon Allocation Environmental Exchanges Inputs (Energy & Materials) Outputs (Air, Water & Waste) Work Environment Impact Potentials Resource Consumption (Energy & Materials) Environmental Impacts (Global Warming, Acidification, Ozone, etc.) Impact on Work Environment

21. The LCA Process Impact Assessment Goal Scope Inventory Assess product Improve product Compare products Design new product Create product specifications Functional Unit Reference product(s) Assessment parameters Important Processes Time Horizon Allocation Environmental Exchanges Inputs (Energy & Materials) Outputs (Air, Water & Waste) Work Environment Impact Potentials Resource Consumption (Energy & Materials) Environmental Impacts (Global Warming, Acidification, Ozone, etc.) Impact on Work Environment

22. Scope • Functional Unit • What provides the service? • Egg tray • Transports 12 eggs from grocery store to home without breaking… • Crane arm • Fits on existing base, lifts at least 400 lbs… • Reference product(s) • Existing products that delivery same or almost same service • Egg trays already in use • Are there existing cranes that deliver ~ same service?

23. Scope (cont.) • Assessment parameters • Environmental Impacts • Resource Consumption • Work Environment… • Important Processes • Time Horizon • While product is manufactured? • While product is in use? • Longterm environmental effects? • Could be hundreds of years or more • Allocation • It may be difficult to allocate environmental impacts • May be multiple products from single processes • Inputs may be byproducts of other processes • Outputs may become inputs for other processes

24. The LCA Process Impact Assessment Goal Scope Inventory Assess product Improve product Compare products Design new product Create product specifications Functional Unit Reference product(s) Assessment parameters Important Processes Time Horizon Allocation Environmental Exchanges Inputs (Energy & Materials) Outputs (Air, Water & Waste) Work Environment Impact Potentials Resource Consumption (Energy & Materials) Environmental Impacts (Global Warming, Acidification, Ozone, etc.) Impact on Work Environment

25. Inventory • Description of all key processes • Inventory of each process exchange with environment • Data collection for each process to make best estimates. • Calculate quantities • E.g., kg of product made x lb CO2 produced /kg

26. Inventory Examples • Gasses that lead to global warming • Gasses that lead to ozone depletion • Gasses that lead to smog formation • Toxic chemicals • Heat • Energy • Degradation of land/habitat

27. The LCA Process Impact Assessment Goal Scope Inventory Assess product Improve product Compare products Design new product Create product specifications Functional Unit Reference product(s) Assessment parameters Important Processes Time Horizon Allocation Environmental Exchanges Inputs (Energy & Materials) Outputs (Air, Water & Waste) Work Environment Impact Potentials Resource Consumption (Energy & Materials) Environmental Impacts (Global Warming, Acidification, Ozone, etc.) Impact on Work Environment

28. Impact Assessment • For the LCA to support decisions, the inventory must be interpreted. Based upon available background knowledge the exchanges are converted to potential impacts on the environment, resource consumption and workers • Most difficult step, can be controversial • Can be achieved in different ways

29. Impact Assessment Methods • Add up like emissions (e.g., CO2, …), resource depletions, etc., and discuss • Estimate impacts from emissions (e.g., Global warming,…), effects of resource depletions, etc., and discuss • Weight various impacts and combine to end up with fewer (as few as one) numbers to compare

30. Hoist-inator – LCA Goal • Service is lift at least 400 lbs at least 24”… • Functional Unit is Crane arm • LCA used to help select between 3 alternative designs !!!! • LCA used to help select best crane in class

31. Hoist-inator - Scope • Aluminum and Plastic members of Crane arm • Production and disposal only • No consideration of impacts during use • Complete reliance on ECO-indicator points calculated by ECO-it Program

32. Hoist-inator - Inventory • Complete reliance on ECO-it • Emissions to air, water, soil • 100’s of different chemicals • Many different materials, processes…

33. Hoist-inator - Impact Assessment • LCA impact assessment is solely based on ECO-indicator points • Higher score is bad • Overall performance is mix of weight, height, time, cost, and LCA • LCA “competes” against other considerations

34. ECO-it (Adopted from Eco-Indicator 99 Manual for Designers) • Developed in Netherlands • Based on European needs and data • Three “Eco”s • Human Health • Number/duration of disease, life-years lost • Causes: Climate change, ozone layer depletion, carcinogenic effects, respiratory effects, ionizing radiation • Ecosystem Quality • Species diversity • Causes: ecotoxicity, acidification, eutrophication, land-use • Resources • Surplus energy needed in future to extract lower quality mineral / fossil resources • Depletion of agricultural / bulk resources considered under land-use

35. Eco-indicators • All environmental impacts converted to Eco-indicator points using weighting method • Point calculated for • Material Production (per kg) • Production Processes (per unit appropriate to process) • Transportation (metric ton-km) • Energy Generation (electricity and heat) • Disposal (per kg) • Negative Eco-points for recycling and reuse • Negative is good!

36. ECO-indicator Methodology • Inventory emissions, resource extractions, land uses related to life cycle of product • Data gathered by ESU-ETH in Zurich • Calculate damage to human health, ecosystem quality, and resources • Mathematic models use inventory data to predict years of life lost, years of disability, loss of species, and surplus energy needed for future extraction of (inferior) resources • Weight the three damage categories to come up with one number • Panel of 365 experts helped to develop weights

37. ECO-it Steps • Establish Purpose • Define Life Cycle • Quantify Materials and Processes • Enter Data into ECO-it • Interpret Results

38. Establish Purpose • Describe product or component to be analyzed • Decide what you intend to do • Analyze one specific product or compare two or more? • Define level of accuracy needed • Do you need to analyze everything or just core parts and/or processes?

39. Establish Purpose - Crane • Define product or product component • Crane with 10 year life (used 10 hrs/week) that can lift >400 lb to height of > 24 in in 4 seconds • LCA is of aluminum and plastic members • Analysis of product or comparison with other product? • Comparison of alternative designs to optimize final design of single product • Level of Accuracy? • Whatever ECO-it will give us

40. Define Life Cycle • Schematic overview of product life cycle, including production, use, and waste processing

41. Define Life Cycle - Crane Aluminum Plastic Pressing Milling, Turning, Drilling Pressure Forming Milling, Turning, Drilling Transport Use Electricity Recycle / Landfill Aluminum Incinerate / Landfill Plastic

42. Quantify Materials and Processes • Determine Functional Unit • Quantify relevant processes • Make assumptions for missing data

43. Quantify - Crane • Parts • How many and how much material in each? • Lump all aluminum and all plastic used into one part each • Processes • How much is pressed or pressure formed? • How much is transported how far? • Energy (Except we’ve decided to exclude this) • What kind and how much? • Disposal • How much is landfilled, incinerated, or recycled?

44. Enter Data and ECO-it calculates • Fill in Form properly • Select parts and processes in ECO-it production, use, and disposal windows • Fill in amounts • ECO-it calculates damage to Human Health, Ecosystem Quality, and Resources and calculates single ECO-indicator point value by weighting method

45. ECO-it: Life Cycle Window

46. ECO-it: Production Window

47. ECO-it: Use Window JUST AN EXAMPLE: WE ARE NOT INCLUDING USE IN OUR LCA

48. ECO-it: Use Window Your Use window will look like this.

49. Enter Data into ECO-it

50. Interpret Results • Which phase of life cycle causes most damage, production, use, or disposal? • Which parts or processes cause most damage? • What effect might any assumption or uncertainties have? • Make conclusions? • Ask the question, has the purpose of the LCA been met?