this lecture unit is part of a set created by mike ashby to help introduce students to materials,...
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This lecture unit is part of a set created by Mike Ashby to help introduce students to materials, processes and rational selection.
The Teaching Resources website aims to support teaching of materials-related courses in Design, Engineering and Science. Resources come in various formats and are aimed primarily at undergraduate education.Some of the resources are open access and students can access them. Others are only available to educators using CES EduPack.
Mike AshbyDepartment of EngineeringUniversity of Cambridge
www.grantadesign.com/education/resources
© M. F. Ashby, 2013For reproduction guidance see back page
Unit 12.
Eco-selection and the
Eco-audit toolIntroducing students to life-cycle thinking
www.grantadesign.com/education/resourcesMike Ashby, 2013
Outline, outcomes and resources
The materials life-cycle
Eco-audits and the audit tool
Case study: PET bottles from France
Resources
Text: “Materials and the Environment”, 2nd Edition (2012) Chapters 1 - 10 Text: “Materials: engineering, science, processing and design”, 2nd Edition, Chapter 20 Text: “Materials Selection in Mechanical Design”, 4th Edition, Chapter 16 Software: CES EduPack with Eco-Audit tool Poster: Wall chart of Eco-properties of materials
Outcomes
An understanding of the material life-cycle
Ability to carry out eco-audits of products
Hands-on session, with exercises
DEMO
www.grantadesign.com/education/resourcesMike Ashby, 2013
Combust Landfill
Life cycle assessment (LCA)
Resources
Emissions and waste
The product life-cycle
www.grantadesign.com/education/resourcesMike Ashby, 2013
Typical LCA output
Aluminum cans, per 1000 units• Bauxite 59 kg
• Oil fuels 148 MJ
• Electricity 1572 MJ
• Energy in feedstock 512 MJ
• Water use 1149 kg
• Emissions: CO2 211 kg
• Emissions: CO 0.2 kg
• Emissions: NOx 1.1 kg
• Emissions: SOx 1.8 kg
• Particulates 2.47 kg
• Ozone depletion potential 0.2 X 10-9
• Global warming potential 1.1 X 10-9
• Acidification potential 0.8 X 10-9
• Human toxicity potential 0.3 X 10-9
Life cycle assessment (LCA)
Full LCA is expensive, and requires great detail and experience – and even then is subject to uncertainty
How can a designer used these data?
ISO 14040 seriesPAS 2050
Roll up into an“eco-indicator” ?
Resource consumption
Emissionsinventory
Impactassessment
www.grantadesign.com/education/resourcesMike Ashby, 2013
Design guidance vs. product assessment
Product specification
Concept
Embodiment
Detail
Market need
Problem statement
ProductionLife cycle
assessment
Eco – audit ability
Design guidance
Product assessment
Alternative schemes
Layout and materials
CAD, FE analysis, optimization, costing
www.grantadesign.com/education/resourcesMike Ashby, 2013
Need: Fast Eco-audit with sufficient precision to guide decision-making
1 resource – energy (oil equivalent)
1 emission – CO2 equivalent Distinguish life-phases
Transport
Eco-audit for design
600
400
300
200
100
0
-100
Ene
rgy
(MJ)
Mat
eria
l
Man
ufac
ture
Tran
spor
t
Use
Dis
posa
l
EoL
cred
it
Energy
Life-energy
Potential benefits
16
14
12
10
8
6
4
2
0
-2
C0 2
equ
iv (
kg)
Mat
eria
l
Man
ufac
ture
Tran
spor
t
Use
Dis
posa
l
EoL
cred
it
Carbon
www.grantadesign.com/education/resourcesMike Ashby, 2013
Eco-design: the strategy (1)T
he
step
s
Explore options with “What if..”s
Analyse results, identify
priorities
Fast eco-audit
Ene
rgy
(MJ)
600
400
300
200
100
0
-100
Mat
eria
l
Man
ufac
ture
Tran
spor
t
Use
Dis
posa
l
EoL
cred
it
Initial design
Use CES to select new Materials
and/or Processes
Recommend actions & assesspotential savings
600
400
300
200
100
0
-100
Mat
eria
l
Man
ufac
ture
Tran
spor
tU
se
Dis
posa
l
EoL
cred
it
Initial and re-designE
nerg
y (M
J)
Material
Minimize: • material in part
• embodied energy
• CO2 / kg
ManufactureMinimize:
• process energy
• CO2/kg
End of LifeSelect:• recyclable materials• non-toxic materials
UseMinimize:• mass• thermal loss• electrical loss
TransportMinimize:
• mass
• distance
• transport type
Use eco-audit to identify Eco-design objective
www.grantadesign.com/education/resourcesMike Ashby, 2013
The CES Eco-audit tool
User interface Bill of materials
Manufacturing process
Transport needs
Duty cycle
End of life choice
User interface Bill of materials
Manufacturing process
Transport needs
Duty cycle
End of life choice
User inputs
Eco database Embodied energies
Process energies
CO2 footprints
Unit transport energies
Recycling / combustion
Eco database Embodied energies
Process energies
CO2 footprints
Unit transport energies
Recycling / combustion
Data from CES
Eco audit model
Eco audit model
Outputs(including
tabular data)
www.grantadesign.com/education/resourcesMike Ashby, 2013
The CES EduPack Eco-audit tool
User interface Bill of materials
Manufacturing process
Transport needs
Duty cycle
End of life choice
User interface Bill of materials
Manufacturing process
Transport needs
Duty cycle
End of life choice
User inputs
Eco database Embodied energies
Process energies
CO2 footprints
Unit transport energies
Recycling / combustion
Eco database Embodied energies
Process energies
CO2 footprints
Unit transport energies
Recycling / combustion
Data from CES
Eco audit model
Eco audit model
Outputs(including
tabular data)
www.grantadesign.com/education/resourcesMike Ashby, 2013
^ 1. Material, manufacture and end of life
Product name:
?
The simple Audit tool: Levels 1, 2 and 3
v 2. Transport ?
v 3. Use ?
v 4. Report ?
1 Component 1 Cast iron 30% 2.4 Casting Recycle
1 Component 2 Polypropylene 0% 0.35 Molding Landfill
Super-Gizmo
Survey chartsSurvey charts
Full reportFull report
HELP at each step
New
www.grantadesign.com/education/resourcesMike Ashby, 2013
Component name Material Process Mass (kg) End of life
CES EduPack materials
tree
Step 1. Material and process energy / CO2
Component 1 Aluminum alloys Casting 2.3 Recycle
Component 2 Polypropylene Polymer molding 1.85 Landfill
Component 3 Glass Glass molding 3.7 Reuse
Total embodied energy Total process energy Total mass Total end of life energy
• Casting
• Forging / rolling
• Extrusion
• Wire drawing
• Powder forming
• Vapor methods
End of lifeoptions
• Reuse
• Refurbish
• Recycle
• Combust
• Landfill
www.grantadesign.com/education/resourcesMike Ashby, 2013
Step 2. Transport
Transport stage Transport type Distance (km)
Stage 1 32 tonne truck 350
Stage 2 Sea freight 12000
Table of transport types: MJ / tonne.kmCO2 / tonne.km
Transport energy
Transport CO2
www.grantadesign.com/education/resourcesMike Ashby, 2013
Step 3. Use phase – static mode
Energy input and output
Power rating
Usage
Usage
Fossil fuel to electric
days per year
hours per day
1.2 kW
365
0.5
Energy conversion path
Fossil fuel to heat, enclosed system
Fossil fuel to heat, vented system
Fossil fuel to electric
Fossil fuel to mechanical
Electric to heat
Electric to mechanical (electric motor)
Electric to chemical (lead-acid battery)
Electric to chemical (Lithium-ion battery)
Electric to light (incandescent lamp
Electric to light (LED)
Total energy and CO2 for use
W
kW
MW
hp
ft.lb/sec
kCal/yr
BTU/yr
www.grantadesign.com/education/resourcesMike Ashby, 2013
Bottled water (100 units)
1 litre PET bottle with PP cap Blow molded Filled in France, transported 550 km to UK Refrigerated for 2 days, then drunk
Product name: PET bottle
Survey chartsSurvey charts
Full reportFull report
Number Name Material Process Mass (kg) End of life
100 Bottles PET Molding 0.04 Recycle
100 Caps Polyprop Molding 0.001 Landfill
100 Water 1.0
Transport
14 tonne truckStage 1 550 km
Fossil to electric 0.12 kW 2 days 24 hrs/day
Use - refrigeration
www.grantadesign.com/education/resourcesMike Ashby, 2013
Output: summary charts
Click on bar for help on impact reduction
Copy or print the chart
Toggle between energy and carbon footprint
Life energy
Man
ufact
ure
Mat
eria
ls
Tran
sport
Use Dispo
sal
End-o
f-life
po
tent
ial
Reducing Material-phase impact
Aim
Minimize embodied energy or CO2 footprint / unit of function.
Actions
Select material with lowest embodied energy and CO2 footprint per unit of function.
Use as large a 'recycled content' in the material as possible.
Use as little material as possible while retaining enough redundancy for safety.
Conflicts
Watch out for conflict with the Use phase. The material with the lowest direct eco-impact may not be the lightest or the cheapest. Use trade-off methods to resolve the conflict.
Reducing Material-phase impact Which phase has the largest impact?
Materials
www.grantadesign.com/education/resourcesMike Ashby, 2013
Actions and comparisons
The audit reveals the most energy and carbon intensive
steps…
… and allows rapid “What if…”
PET Glass ?
www.grantadesign.com/education/resourcesMike Ashby, 2013
Product name: PET bottle
Number Name Material Process Mass (kg) End of life
100 Bottles PET Molding 0.04 Recycle
100 Caps Polyprop Molding 0.001 Landfill
100 Water 1.0
Transport
14 tonne truckStage 1 550 km
Fossil to electric 0.12 kW 2 days 24 hrs/day
Use - refrigeration
Change the materials
1 litre glass bottle with aluminum cap Glass molded Filled in France, transported 550 km to UK Refrigerated for 2 days, then drunk
Soda glass Glass mold 0.45
Aluminum Rolling 0.002
PET bottleGlass bottle
Copy of current project
New project
Saved project
www.grantadesign.com/education/resourcesMike Ashby, 2013
Actions and comparisons
The fast comparison allows design
decisions on-the-fly
What if…….100% recycled PET?
Actions
Use as large a 'recycled content' in the material as possible.
Reducing impact
=
Virgin PET
=
Glass
www.grantadesign.com/education/resourcesMike Ashby, 2013
Actions and comparisons
Set Recycle content to 100%
Can explore:
Material choice
Recycle content
Transport mode
Transport distance
Use pattern
Electric energy mix
End of life choice
Many projects available as project files.
ClickCompare with….Copy of current
content
=
Virgin PET
=
Glass
=
Recycled PET
www.grantadesign.com/education/resourcesMike Ashby, 2013
Electric kettle
6 minutes per day
300 days per year
3 years
Use
12,000 km, air freight
250 km 14 tonne truckTransport
Bill of materials and processes
2 kW electric kettle
Made SE Asia Air freight to UK Life: 3 years
www.grantadesign.com/education/resourcesMike Ashby, 2013
Eco audit: the jug kettle
What do we learn?
Little gained by change of material for its own sake
Much gained by insulation – double wall with foam or vacuum
Or seek new concept: hot water on the fly – only as much as needed
Use is 88%of life-energy
www.grantadesign.com/education/resourcesMike Ashby, 2013
So what?
Tool 1. Eco-audits allows students to implement quick, approximate “portraits” of energy / CO2 character of products. (This Unit)
CES EduPack has two tools-sets to help explore the materials dimension of environmental design
Tool 2. Selection strategies allows selection to re-design products to meet eco-criteria, using systematic methods. (Unit 13)
Eco-audits reveal the eco-fingerprint of products and suggest approaches to making them less environmentally damaging.
Project files for many of the audits shown in the spread of eco-fingerprints can be down loaded from the Granta Website, allowing students to try alternative assumptions.
www.grantadesign.com/education/resourcesMike Ashby, 2013
Also Available for Sustainability
• Exercises with Worked Solutions
• Other Lecture Units
• White Papers
• Interactive selection case studies
• Webinar recording
• Poster
• Sample Eco Audit Project Files
• Links to other good resource sites
• Eco Indicator Database
Eco Design & Eco Audits
Materials and Sustainable Development
http://teaching.grantadesign.com/open/eco.htm
www.grantadesign.com/education/resourcesMike Ashby, 2013
Lecture Unit Series
These PowerPoint lecture units, as well as many other types of resources, are on the Teaching Resource Website.
Finding and Displaying Information
Unit 1 The Materials and Process Universe: families, classes, members, attributes
Unit 2 Materials Charts: mapping the materials universe
Unit 3 The Elements: property origins, trends and relationships
Material Properties
Unit 4 Manipulating Properties: chemistry, microstructure, architecture
Unit 5 Designing new materials: filling the boundaries of materials property space
Selection
Unit 6 Translation, Screening, Documentation: the first step in optimized selection
Unit 7 Ranking: refining the choice
Unit 8 Objectives in Conflict: trade-off methods and penalty functions
Unit 9 Material and shape
Unit 10 Selecting Processes: shaping, joining and surface treatment
Unit 11 The Economics: cost modelling for selection
Sustainability
Unit 12 Eco Selection: the eco audit tool
Unit 13 Advanced Eco Design: systematic material selection
Unit 14 Low Carbon Power: resource intensities and materials use
Special Topics
Unit 15 Architecture and the Built Environment: materials for construction
Unit 16 Structural Sections: shape in motion
Unit 17 CES EduPack Bio Edition: Natural and man-made implantable materials
Unit 18 Materials in Industrial Design: Why do consumers buy products?
Unit 19 Advanced Databases: Level 3 Standard, Aerospace and Polymer
Advanced Teaching and Research
Unit 20 Hybrid Synthesizer: modelling composites, cellular structures and sandwich panels
Unit 21 Database Creation: using CES constructor in research
Unit 22 Research: CES Selector and Constructor
Unit 23 Sustainability: sustainability and materials selection
Unit 24 The Polymer Edition
Unit 25 The Aerospace Edition
www.grantadesign.com/education/resourcesMike Ashby, 2013
www.grantadesign.com/education/resources
M. F. Ashby, 2013
Granta’s Teaching Resources Website aims to support teaching of materials-related courses in Engineering, Science and Design.
The resources come in various formats and are primarily aimed at undergraduate students.
This resource is one of 25 lecture units created by Professor Mike Ashby.
The website also contains resources donated by faculty at the 800+ universities and colleges worldwide using
Granta’s CES EduPack.
The teaching resource website contains both resources that require the use of CES EduPack and those that don’t.
Some of the resources, like this one, are open access.
AuthorProfessor Mike Ashby
University of Cambridge, Granta Design Ltd.
www.grantadesign.com/education
www.eng.cam.ac.uk
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AccuracyWe try hard to make sure these resources are of a high quality. If you have any suggestions for improvements, please contact us by email at teachingresources@grantadesign.com
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