2.810 Eco-accounting for manufacturingT. G. GutowskiOct 20, 2006= key reference materialsReferences• Dahmus, J. and T. Gutowski. "An Environmental Analysis of Machining," Proceedings of the 2004 ASME International Mechanical Engineering Congress and RD&D Exposition, Anaheim, California, USA, November 13-19, 2004. (pdf available)• Dalquist, S. and T. Gutowski. "Life Cycle Analysis of Conventional Manufacturing Techniques: Sand Casting," Proceedings of the ASME International Mechanical Engineering Congress and RD&D Exposition, Anaheim, California, USA, November 13-19, 2004. (pdf available) • Thiriez, A. and T. Gutowski. “An Environmental Analysis of Injection Molding," IEEE International Symposium on Electronics and the Environment, San Francisco, California, USA, May 8-11, 2006. (pdfavailable)• Gutowski, Dahmus and Thiriez, “A Thermodynamic Characterization of Manufacturing Processes, Working Paper 3 –TGG-LMP-2006Mining Primary Mfg Distribution Use Disposition0m&8m&kipm&kopm&0m&8m&kipm&kopm&0m&8m&kipm&kopm&0m&8m&kipm&kopm&0m&8m&kipm&kopm&0m&8m&kipm&kopm&Recycle, Remanufacture, ReuseLife Cycle FrameworkCategories of Impacts• Resources usedusually focus on materials, but also land and eco-system services particularly if they are non-renewable, limited in supply, or highly problematic• Emissionsparticularly those that are hazardous, but also those that disrupt eco-system functioningLife Cycle Perspective• boundaries start from earth as the source,and return to earth as the sink• evaluation is often focused on a product or service• tracking is of materials• time stands stillLCA softwarehttp://www.life-cycle.org/LCA_soft.htm• Boustead Consulting Database and Software• ECO-it: Eco-Indicator Tool for environmentally friendly design - PRéConsultants • EDIP - Environmental design of industrial products - Danish EPA • EIOLCA- Economic Input-Output LCA at Carnegie Mellon University • GaBi 4 - (Ganzheitlichen Bilanzierung -Five Winds International/University of Stuttgart (IKP)/PE Product Engineering • IDEMAT - Delft University Clean Technology Institute InterductEnvironmental Product Development • KCL-ECO 3.0 - KCL LCA software • LCAiT - CIT EkoLogik (Chalmers Industriteknik) • SimaPro 6 for Windows- PRé Consultants • TEAM(TM) (Tools for Environmental Analysis and Management) -Ecobalance, Inc. • Umberto - An advanced software tool for Life Cycle Assessment - Institut fürUmweltinformatikInventory from LCI softwareSimaPro 6.0 Date: 7/28/2005 Time: 1:33:53 PMTitle: Analyzing 1 kg processing 'Machining aluminium I'Method: / CompartmeAll compartmentsIndicator: InventoryCategory: Skip unuseNoRelative moNonCut-off: 0%1 Methane Raw kg 0.000283 x 0.0002832 Wood, unspecified, standing/kg Raw biotic kg 0.000424 x 0.0004243 Baryte, in ground Raw in ground kg 0.0000469 x 0.00004694 Bauxite, in ground Raw in ground kg 0.0000127 x 0.00001275 Chromium, in ground Raw in ground kg 0.000000457 x 0.0000004576 Clay, bentonite, in ground Raw in ground kg 0.0000133 x 0.00001337 Coal, 18 MJ per kg, in ground Raw in ground kg 0.0401 x 0.04018 Coal, brown, 8 MJ per kg, in ground Raw in ground kg 0.000573 x 0.0005739 Cobalt, in ground Raw in ground kg 9.1E-13 x 9.1E-1310 Copper, in ground Raw in ground kg 0.00000339 x 0.0000033911 Gas, natural, 35 MJ per m3, in ground Raw in ground m3 0.0215 x 0.021512 Gas, off-gas, oil production, in ground Raw in ground m3 0.00015 x 0.0001513 Iron, in ground Raw in ground kg 0.000373 x 0.00037314 Lead, in ground Raw in ground kg 2.92E-08 x 2.92E-08TotalMachining aluminium IElectricity Netherlands ETH INoSubstance CompartmentSub-compartmentUnitStreamlined Life Cycle Analysis5554535251Refurbishment, Recycling, Disposal4544434241Product Use3534333231Product Delivery2524232221Manufacturing1514131211Extraction andRefiningGaseous ResiduesLiquid ResiduesSolid ResiduesEnergy UseMaterials ChoiceLife Cycle StagesGraedel 1998Light Bulbs and MercuryAllen and ShonnardOutline1. Materials Production2. Manufacturing Processes1. electrical energy requirements2. waste working materials 3. waste auxiliary materials4. emissions3. Product RecyclingProcess Energy & Material FlowsENERGY PROCESSHEATWastes and EmissionsMATERIALS:WorkingAuxiliaryMATERIALS:ProductsMaterials Production1. Mining and Milling• underground Vs strip mining• ore grade “g” = concentration2. Smelting and Refining3. Energy to make the energy• electricityEnergy to make energy:consider the energy required to make electricitychemical to thermal 90-98%thermal to mechanical 40-45%mechanical to electrical 98-99%taking the median values.94 x .425 x .985 = .39Use 33% for US gridSource: http://encarta.msn.com/media_461533479_761561391_- 1_1/Open- Pit_Copper_Mine_Utah.htmlOpen-Pit Copper Mine, Utahdrilling rig in underground mine in the Głogow area of PolandCopper concentrations in this area are about 2%energy requirements for mining and milling, possible future trendsChapman and Roberts p 113 & 116underground ~ 1000/g (MJ/t metal)open pit ~ 400/g (MJ/t metal)Source: http://encarta.msn.com/media_461547490_761561391_- 1_1/Smelting_Copper.htmlCopper SmeltingCopper Smelting ProcessSource: http://encarta.msn.com/media_461533478_761561391_- 1_1/Production_of_Copper.html1) Copper Ore (~ 1%) → Concentrate (~20 to 35%) • milling, flotation, separation2) Roasting and SmeltingCopper Smelting ProcessCuFeS2Cu2S (matte)2FeOSiO2(slag)0.34 -1% CuCu (blister)~98% Cu3) Roasting and Smelting 2FeS+3O2Æ 2FeO+2SO2xFeO + ySiO2Æ(FeO)x·(Si02)y-slag2Cu2S + 3O2Æ 2Cu2O + 2SO2Cu2S + 2Cu2O Æ 6Cu + SO2 (blister copper ~98%)4) Electrolytic Refining (99.99%)sulfuric acid electrolyteanode mud (1:100) contains (Cu, Ag, As, Se, Bi, ..Au, Te…)Copper Smelting ProcessRef. Smil 1999Material and Energy Requirements to Produce Aluminum from Bauxite ref. Smil 1999Primary Vs Secondary Mat’lsChapman and Roberts 1987the fuel requirements of smeltingPolymer ProductionLargest Player in the Injection Molding LCISources HDPE LLDPE LDPE PP PVC PS PC PETBoustead 76.56 77.79 73.55 72.49 58.41 86.46 115.45 77.14Ashby 111.50 ------- 92.00 111.50 79.50 118.00 ------- -------Patel ------- ------- 64.60 ------- 53.20 70.80 80.30 59.40Kindler/Nickles [Patel 1999]------- ------- 71.00 ------- 53.00 81.00 107.00 96.00Worrell et al. [Patel 1999]------- ------- 67.80 ------- 52.40 82.70 78.20E3 Handbook [OIT 1997]131.65 121.18 136.07 126.07 33.24 ------- ------- -------Energieweb 80.00 ------- 68.00 64.00
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