EcoDesign Pilot Project: Eco-Compressor

1. EcoDesign Pilot Project:Eco-Compressor Dr.Thumrongrut Mungcharoen Expert, Cleaner Technology Advancement Program, National Metal and Materials Technology Center & Director, Cleaner Technology & EcoDesign Research Unit, Kastesart University (With the cooperation of Kulthorn Premier Company Limited)

2. Contents 1. Trade and Environment 2. Introduction to EcoDesign 3. EcoDesign Case study: Eco-Compressor 4. Current Situation of Eco-Compressor Project 5. Conclusions

3. 1950 1972 1997 2050 Population (billion) 2.5 3.8 5.8 12.0 Megacities (>8million) 2 9 25 Food Production(cal/capita-day) 1980 2450 2770 Fish Catch (million tons/yr) 1.9 58.0 91.0 Water Use (km3/yr) 1300 2600 4200 Rainforest Cover(% of ‘50 level) 100 85 70 Elephants (million) 6.0 2.0 0.6 CO2 Emission (billion tons/yr) 1.6 4.9 7.0 Atmospheric CFC (ppb) -- 1.4 3.0 Ref: C.C.Chao, Industrial Technology Research Institute, Taiwan 1. Trade and Environment

4. Source: EGG 2004+ Materials EU Legislation

5. Basic Environment Law Basic Law for Establishing the Recycling-based Society Law for the Promotion of the Effective Utilization of Resources (Promote “3Rs) Waste Disposal and Public Cleaning Law Recycling lawsfor individualfields Containers and Packaging Recycling Law Home Appliances Recycling Law Construction Materials Recycling LawFood Waste Recycling Law Automobile Recycling Law Fluorocarbons Recovery and Destruction Law Law on Promoting Green Purchasing Japan legislation(all laws below are already enforced) Source: Eco-management Institute (Japan)

6. Solution Need to go“Green” GREEN COMPETITIVENESS Tools: CT + LCA + EcoDesign

7. 2. Introduction to EcoDesign • Product Designเป็นตัวบ่งชี้ที่สำคัญ เกี่ยวกับ ความสามารถในการแข่งขัน ของผู้ผลิต • National Research Council, USA:ประมาณการว่า70% or more of the costs of product development, manufacture and useถูกกำหนดตั้งแต่ช่วงinitial design stages • Bad designนำไปสู่inefficient use ofresourcesและ excessive waste • Trade Barriersโดยใช้ประเด็นทางสิ่งแวดล้อมมีมาก(packaging / hazardous substances / product recyclability etc.)

8. What is EcoDesign? การออกแบบเชิงนิเวศเศรษฐกิจ (Economic & Ecological Design; EcoDesign):กระบวนการที่ผนวกแนวคิดด้านเศรษฐกิจและด้านสิ่งแวดล้อมเข้าไปในขั้นตอนการออกแบบผลิตภัณฑ์หรือกระบวนการ โดยพิจารณาตลอดวัฏจักรชีวิตของผลิตภัณฑ์ ซึ่งจะช่วยลดต้นทุนในแต่ละขั้นตอนของการพัฒนาผลิตภัณฑ์และลดผลกระทบต่อสิ่งแวดล้อมไปพร้อมๆ กัน ทำให้ส่งผลดีต่อธุรกิจ ชุมชน และสิ่งแวดล้อม ซึ่งเป็นแนวทางไปสู่การพัฒนาอย่างยั่งยืน

9. เป้าหมาย2อย่าง ของEcoDesign Better Resource Management Waste Prevention พยายามให้ง่ายต่อ: Re-manufacturing รีไซเคิล Energy recovering ลด : น้ำหนัก ความเป็นพิษ พลังงาน ยืด : อายุการใช้งาน (From Bishop, 2000)

10. ‘State of the art’ in eco-design in the Japanese electronics sector • Change • Environment is key R&D priority • Recycling-orientated Economy • Environmental (technology) businesses • 3Rs • Home Appliances Recycling Law (HARL) • Law for Promotion of Effective Utilisation of Resources (LPEUR) (Ref: Martin Charter & Tom Clark, CfSD, UK)

11. ‘State of the art’ in eco-design in the Japanese electronics sector (cont.) • Recycling infrastructure • New phase of greening • Green Purchasing Law (GPL) • Green procurement • Green new product development • Environmental accounting • LCA • Type II & III Labels (Ref: Martin Charter & Tom Clark, CfSD, UK)

12. 0 • New Concept Development 7 • Dematerialisation • Shared use of the product • Optimization of end-of-life system • Integration of functions • Reuse of product • Functional optimization of product (components) • Remanufacturing/refurbishing 1 • Recycling of materials • Selection of low-impact materials • Clean incineration - - • Non-hazardous materials + + • Non-exhaustable materials 6 • Low energy content materials • Recycled materials • Optimization of initial life-time • Recyclable materials • Reliability and durability • Esay maintenance and repair 2 • Modular product structure • Reduction of material • Classic design • User taking care of product • Reduction in weight • Reduction in (transport) volume 5 3 • Reduction of the environmental • Optimization of production techniques impact in the user stage • Alternative production techniques • Low energy consumption • Fewer production processes 4 • Clean energy source • Low/clean energy consumption • Few consumables needed during use • Low generation of waste • Efficient distribution system • Clean consumables during use • Few/clean production consumables • Less/clean packaging • No energy/auxiliary material use • Efficient transport mode Priorities for the new product • Efficient logistics Existing product UNEP Eco-Strategies Wheel

13. EcoDesign Process Flow EcoDesign Tools EcoDesign Phases Target Product / Parts Phase I Planning Analysis and Evaluation of the Present Design QFDE Phase II Analysis & Generation Product Concept Making Conceptual Design Phase III Design & Development DFE Checklist Qualitative Design Review Detailed Design LCA Eco-Indicator Quantitative (Final) Design Review Phase IV Verifying & Approval Approval

14. 3. EcoDesign Case Study:Eco-Compressor • Collaborative project between government and industry strategic partner • Signing an cooperative agreement between MTEC and SUE on August 27, 2003 • As a pilot project of the NETH program of GMTAP

15. Objectives • To improve design of compressor parts by changing materials from cast iron to sintering steel • To compare environmental impacts of a conventional • & a new prototype of compressor using LCA • To evaluate performance of the new prototype by running a trial test in a standard condition (cooling capacity, noise & vibration, enduration & reliability, etc.)

16. Working team • Dr.Pomthong Malakul Na Ayudhaya • Dr.Thumrongrut Mungcharoen • Dr.Ruangdaj Tongsri • Ms.Chantana Yuvaniyama • Mr.Seksan Papong • Mr.Bhanu Vetayanukul • Ms.Kirana Chomkumsri • Ms.Phirada Pruitichaiwiboon MTEC Team KPC Team • Mr.Chidchanogk Vatchanarat • Mr.Supachoke Boonkum • Mr.Poramate Somsinsawasdi • Mr.Khamnoon Jampathongthed

17. Expected Output of Pilot Project • A good demonstration project for Thailand that combines both LCA and EcoDesign into one project. • Creat a group of core researchers who have practical experience in LCA and EcoDesign. • The production processes of motor case + cylinder & piston + slider are expected to be reduced ~50% by changing from “Casting” to “Sintering”. Reduce energy, resources, and environmental impacts from the production. • Developing strong relationship among MTEC & private company & Japanese counterparts (e.g.JODC, JETRO)

18. 4. Current situation • Eco-Design Part • JODC-Expert dispatch: Mr.Akira Arai, visit 3 times (7-11 June 04, 22-26 Nov 04, 7-11 Feb 05) • Review design & detail design of the compressor parts • Making mold prototypes (connecting rod & piston) • Finite Element Analysis (connecting rod & crankcase) • Making eco-parts (connecting rod & piston) • Friction wear resistance test (bush + connecting rod & piston) • Performance & reliability test • Mechanical testing of the connecting rod

19. Mr.Akira Arai (3 Visits): Advice on compressor design

20. Items Temporary std. Con-rod & piston (P/M parts) Performance data Cooling cap. Input P. EER COP Noise (BTU/hr) (W) (BTU/W) (W/W) (dB) 468.3 476.2 91.8 93.7 5.099 5.082 1.503 1.489 36.46 36.3 Performance test

21. LCA part • Goal • to determine the net improvement of environmental impact of a new prototype compressor (comparison of a conventional & new prototype compressor)

22. Scope • Product: • Reciprocating compressor (model 110 W) • Functional unit • Refrigerated temperature at 5o C for 10 years with an ambient temperature at 32o C

23. Electricity Transport System boundary: current model • Cast iron parts • manufacturing • Motor case • Cylinder • Piston • Slider • Crank shaft Machining Refrigerator plant Washing Compressor Extraction & raw materials manufacturing Main assembly Painting Usage Other parts manufacturing Compressor disposal Disposal • Silicon steel • Copper wire • Plastic ins. Stator assembly Compressor plant • Silicon steel • Aluminum ingot Rotor assembly • Copper tube • Steel sheet • Small press parts • etc. Shell assembly Parts preparation Disposal scenario Production waste

24. Electricity Transport System boundary: new model • Cast iron parts • Crank shaft Machining • P/M parts • Crank case • Con-rod • Piston Refrigerator plant Washing Compressor Extraction & raw materials manufacturing Main assembly Painting Usage Other parts manufacturing Compressor disposal Disposal • Silicon steel • Copper wire • Plastic ins. Stator assembly Compressor plant • Silicon steel • Aluminum ingot Rotor assembly • Copper tube • Steel sheet • Small press parts • etc. Shell assembly Parts preparation Disposal scenario Production waste

25. Compressor Factory Compressor Inventory data of the compressor Emission to Air CO xxx kg CO2 xxx kg NOX xxx kg SOX xxx kg VOC xxx kg H3PO4 xxx kg Mn xxx kg Ethylene Glycol xxx kg Materials/Resources Steel xxx kg Cast Iron xxx kg Copper xxx kg Al xxx kg Plastic xxx kg Paint xxx kg BA oil xxx L Gear Oil xxx L NUTO Oil xxx L Telluse Oil xxx L Cutta Oil xxx L Macron Oil xxx L Lubricant xxx kg Trichloroethylene xxx L Nano water xxx L Water xxx L Emission to Water pH 7.4 BOD xxx kg COD xxx kg SS xxx kg Grease & Oil xxx kg Waste water xxx L Energy Uses Electricity xxx kWh LPG xxx m3 Fuel Oil xxx L Solid Waste Steel scrap xxx kg Cast iron waste xxx kg

26. Data quality • Foreground data • Collect data from compressor factory • Background data • LPG & Fuel oil (software database) • Electricity grid mix (Thai database) • Materials • Cast iron (from supplier) • Sintered steel (from supplier)

27. Project Plan of the Eco-Compressor

28. 5. Conclusions & future activities • Design part • New model – noise reduction • Focus on lubrication performance of the cylinder part • LCA part • collect & verify data • impact assessment

29. CONTACT : • Dr. Thumrongrut Mungcharoen • Dr. Pomthong Malakul Na Ayudhaya • and Mr. Seksan Papong • Cleaner Technology Advancement Program • National Metal and Materials Technology Center (MTEC) • National Science and Technology Development Agency (NSTDA) • 73/1 Rama 6 Rd., Rajadhevee, Bangkok, Thailand 10400 • Tel: (662) 644-8150-80 ext. 434, 435 • Fax: (662) 644-8077 • E-mail: fengtrm@ku.ac.th, pomthong@mtec.or.th, seksanp@mtec.or.th ( CTAP )