this lecture unit is part of a set created by mike ashby to help introduce students to materials,...

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


Combust Landfill

Life cycle assessment (LCA)

Resources

Emissions and waste

The product life-cycle


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


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


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


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


The CES Eco-audit tool

User interface Bill of materials

Manufacturing process

Transport needs

Duty cycle

End of life choice



Transport needs

Duty cycle

End of life choice

User inputs

Eco database Embodied energies

Process energies

CO2 footprints

Unit transport energies

Recycling / combustion


Process energies

CO2 footprints



Data from CES

Eco audit model

Eco audit model

Outputs(including

tabular data)


Typical record showing eco-properties


The CES EduPack Eco-audit tool



Transport needs

Duty cycle

End of life choice



Transport needs

Duty cycle

End of life choice

User inputs


Process energies

CO2 footprints




Process energies

CO2 footprints



Data from CES

Eco audit model

Eco audit model

Outputs(including

tabular data)


^ 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


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


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


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


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


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


Actions and comparisons

The audit reveals the most energy and carbon intensive

steps…

… and allows rapid “What if…”

PET Glass ?


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



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



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


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


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


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.


Pause for Demo


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


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/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

ReproductionThis work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 3.0 Unported License.

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this lecture unit is part of a set created by mike ashby to help introduce students to materials,...

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