Environmentally Conscious Design & Manufacturing

1. Environmentally Conscious Design & Manufacturing Class4: Life Cycle Analysis-Design Prof. S. M. Pandit

2. Life Cycle Analysis - Design Agenda: - Motivation and Introduction - Product Life Cycle - Systems View - Product Design - Green Design Strategies

3. Motivation - 1 Define Scope Inventory analysis Impact analysis Manufacture Improvement analysis RERP Steps in the life-cycle assessment of a product

4. Motivation - 2 Materials acquisition Principal products Formulation, processing, and manufacturing Co-products Materials Product distribution Water effluents Energy Product use Airborne emissions Water Recycle:Products, components, materials Solid Waste Air Waste management Other environmental interactions The elements of a life-cycle inventory analysis

5. Motivation - 3 • A life cycle inventory and impact assessment provides a snapshot of the environmental features of • - Products or • - Processes Hazards and Risks Discrete Products: - Machined shaft - Gearbox - Washing Machine Milling operation Oil refining Beverage mixing and bottling

6. Introduction -1 Power Generation Product Life Cycle Use • “Waste” • Energy • Materials • Fluids Post Use Manufacturing Material Handling and Logistics Raw Material Extraction

7. Introduction -2

8. Product Life Cycle - 1 Use Manufacturing Post Use DESIGN Product / Process - Disposal - Recycling - Remanufacturing Raw material extraction

9. Product Life Cycle - 2 - Design for disassembly methodologies - Design for recycle and reuse methodologies - Design for decommissioning of equipment Environment Product functionality and quality Cost

10. Product Life Cycle - 3 Design factors - Env. - x Compliance Environment Assembly Orderability Manufacturabiliy Material Logistics and Component Applicability Design for X Reliability Safety and Liability Prevention Serviceability Testability

11. Systems View - 1 • Environment • Cost • Function .. Product Design Process Models ‘Usage’ models Recycling / Reuse / Biodegradation / Chemical degradation / Physical degradation & collection Material Handling and Logistics Discrete Event Models - I/O response from simulation Power Generation Idealized models with empirical weights

12. Systems View - 2 • Product attributes • Weight • Size • Can be palletized? • Handle with care? • Cost Material Handling and Logistics Speed of movement? Distance to be moved? Sensor (vision?) Control (fuzzy?)

13. Systems View - 3 Product attributes • Material Handling and Logistics • Discrete event Model • Simulation • Control • Movement • Queuing Time Cost Handling capacity Success / Failure statistics

14. Product Design(Bridge between Design Islands) “Functional Requirements” (Does it do the job?) “Materials” Strength Creep resistance Thermal & Electrical properties “Aesthetic Requirements” “Mechanical” Power output Kinematics Velocity ratios “Environmental Factors” (Does it do the job?)

15. Green Design - 1 • Multidisciplinary research that would result in validated models of physical processes that also incorporate • life cycle, • environmental, and • economic parameters-as well as • traditional process control parameters.

16. Green Design - 2 • Ideally these models would • use the best computer technology- • but be adaptable to manufacturing environments. • Tied directly to the modeling was the need for correlation of • materials/chemical properties and • structure with processing parameters.

17. Green Design - 3 Closely related is instrumentation research that can enhance process monitoring, & control The need for novelty and creativity in solving technical problems is stressed throughout. To attain goals of total sustainability simple enhancements of traditional methodology will not usually be sufficient.

18. Green Design - 4 • New approaches to processing • Sensors that monitor phenomena that are unmonitorable today • New materials that survive high temperatures and corrosive environments and last "forever," • New technologies for energy efficiency and clean combustion • New ways to separate effluents • New approaches to catalysis • Without basic research these leaps are unlikely to occur.

19. Green Design - 5 Every industry will need highly specific chemical sensors for applications such as process control, process monitoring, ambient monitoring, and leak detection. These sensors must be fast, reliable, robust, inexpensive, sensitive, miniature, on-line capability, local, remote, for multicomponent analysis. In addition, all these features must be available for sensing in gaseous and liquid environments (including air and water) where the conditions may be considered harsh or even hostile.

20. Green Design - 6 Given the fact that water quality concerns are prominent throughout industry, another common need is for improved water quality sensors with the same characteristics noted above for chemical sensors but focusing almost exclusively on those parameters measured for regulatory purposes including BOD, TOC, and particulates. Similarly, there is a need for improved air quality sensors to accurately and rapidly measure extremely low quantities of volatile organic chemicals and particulates. In particular, measurements of particle size distributions were identified as a specific need. It will be increasingly necessary to develop methodologies for multi-point as well as multi-species monitoring.

21. Green Design - 7 Another research need, common to all of the industries discussed, falls in the general category of physical sensors. It was found that the need for fast, reliable, inexpensive physical sensors that can operate in harsh environments currently exists and that need will certainly increase in the future. Even a need for improved temperature sensors was identified. Other specific sensing needs include (1) particle size distribution, (2) non-destructive evaluation (NDE) of near-net shape to reduce material waste, (3) structural integrity so as to avoid catastrophic system failure resulting in release of process fluids, (4) rheometry especially for complex fluids such as slurries, (5) multiphase flow parameter sensors, and (6) leak detection.

22. Green Design - 8 The final common element centered on the need for improved data processing and management. With the large scale increase in sensors and rapid monitoring devices it is obvious that careful attention must be paid to the collection and use of large amounts of data. Error detection and identification, multiple sensor data "fusion" (i.e., integration, interpretation), and robust control methods must be enhanced.