Eco Selection and The Eco Audit Tool Lecture Unit 12 PDF

Unit 12.
Eco-selection
and the
Eco-audit tool
Introducing students to life-cycle thinking
Mike Ashby
Department of Engineering
University of Cambridge
M. F. Ashby, 2011
For reproduction guidance see back page
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.
www.grantadesign.com/education/resources
Outline
Material consumption and life-cycle
LCA - problems and solutions
Eco-audits and the audit tool
Strategy for materials selection
Demo
Exercises
Resources
Text: Materials and the Environment, Chapters 1 - 9
Text: Materials: engineering, science, processing and design, Chapter 20
Text: Materials Selection in Mechanical Design, Chapter 16
Software: CES Edu with Eco-Audit tool
Poster: Wall chart of Eco-properties of materials
M. F. Ashby, 2011
Material production
Concern 1: Resource consumption, dependence
96% of all
material
Usage
20% of
Global
energy
M. F. Ashby, 2011
Carbon to atmosphere
Concern 2: Energy consumption, CO2 emission
20% of all
carbon to
atmosphere
M. F. Ashby, 2011
The product life-cycle

Resources
Life cycle
assessment (LCA)
Emissions and waste
M. F. Ashby, 2011
Combust
Landfill
Life cycle assessment (LCA)

ISO 14040 series
PAS 2050
Resource
consumption
Emissions
inventory
Impact
assessment
Typical LCA output

Aluminum cans, per 1000 units
Bauxite
Oil fuels
Electricity
Energy in feedstock
Water use
Emissions: CO2
Emissions: CO
Emissions: NOx
Emissions: SOx
Particulates
Ozone depletion potential
Global warming potential
Acidification potential
Human toxicity potential
59
kg
148
MJ
1572
MJ
512
MJ
1149
kg
211
kg
0.2
kg
1.1
kg
1.8
kg
2.47
kg
0.2 X 10-9
1.1 X 10-9
0.8 X 10-9
0.3 X 10-9
Roll up into an
eco-indicator ?
Full LCA expensive, and requires great detail and skill and even
then is subject to uncertainty
How can a designer used these data?
M. F. Ashby, 2011
Design guidance vs. product assessment

Market need
Problem statement
Alternative schemes
Concept
Layout and
materials
Embodiment
CAD, FE analysis,
optimization, costing
Detail
Eco audit
ability
Product specification
Production
M. F. Ashby, 2011
Life cycle
assessment
Eco-audit for design

Need: Fast Eco-audit with sufficient precision to guide decision-making
1 resource energy (oil equivalent)
1 emission CO2 equivalent
Distinguish life-phases
16
600
14
C02 equiv (kg)
Energy (MJ)
400
300
200
100
12
10
8
6
4
2
0
0
-2
-100
This is the life-energy and life-CO2
These are potential benefits
(as prescribed in ISO 14040 and PAS 2050)
(could be recovered at end of life)
M. F. Ashby, 2011
Eco-aware design: the strategy (1)

The steps
Fast
eco-audit
Analyse
results, identify
priorities
Explore
options with
What if..s
600
600
What if ..
400
400
300
300
Energy (MJ)
Energy (MJ)
Initial design
200
100
200
100
-100
-100
M. F. Ashby, 2011
Different material?
Eco-aware design: the strategy (2)

Look at the first three steps
The steps
Explore
options with
What if..s
Analyse
results, identify
priorities
Fast
eco-audit
Use CES to
select new Materials
and/or Processes
Recommend
actions & assess
potential savings
600
400
Energy (MJ)
Use eco-audit to
indentify
design objective
300
200
100
0
-100
Material
Manufacture
Transport
Minimize:
Minimize:
Minimize:
material in part
embodied energy
CO2 / kg
process energy
CO2/kg
mass
distance
transport type
M. F. Ashby, 2011
Use
Minimize:
mass
thermal loss
electrical loss
End of life
Select:
non-toxic materials
recyclable
materials
The CES Eco-audit tool

Data from CES
User inputs
User interface
Eco database
Bill of materials
Embodied energies
Manufacturing process
Process energies
Transport needs
CO2 footprints
Duty cycle
Unit transport energies
End of life choice
Recycling / combustion
Eco audit
model
Outputs
(including
tabular data)
M. F. Ashby, 2011
Typical record showing eco-properties
M. F. Ashby, 2011
The simple Audit tool: Levels 1, 2 and 3
Add record
Eco Audit
Todays Webex
Webex Feb 10 at 4.00 PM UK time
Synthesizer
Options.
^ 1. Material, manufacture and end of life ?
1
Component 1
Component 2
How
many?
Name
Cast iron
Polypropylene
Choose
material from
CES DB tree
30%
2.4
Casting
Recycle
0%
0.35
Molding
Landfill
Set recycle
content
0 100%
Enter
mass
Choose Choose end-ofprocess

life path
v 2. Transport ?
v 3. Use
v 4. Report
M. F. Ashby, 2011
HELP at
each step
Material and process energy / CO2

Component name
Component 1
Material
Aluminum alloys
Process
Casting
Casting
Forging / rolling
Extrusion
Wire drawing
Powder forming
Vapor methods
Mass (kg)
2.3
End of life
Recycle
End of life
options
Available
processes
Reuse
Refurbish
Recycle
Combust
Landfill
CES EduPack
materials
tree
Total embodied energy
Total process energy
Total mass
Total end of life energy
M. F. Ashby, 2011
Transport
Transport stage
Transport type
Stage 1
32 tonne truck
Stage 2
Sea freight
Distance (km)
350
12000
Transport energy
Transport CO2
Table of transport types:

MJ / tonne.km
CO2 / tonne.km
M. F. Ashby, 2011
Use phase static mode
Energy input and output

Power rating
Usage
Usage
Fossil fuel to electric

1.2
365
0.5
Total energy and CO2 for use
kW
W
days per year
kW
MW
hours
hpper day
ft.lb/sec
kCal/yr
BTU/yr
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)
M. F. Ashby, 2011
Bottled water (100 units)

1 litre PET bottle with PP cap
Blow moulded
Filled in France, transported 550 km to UK
Refrigerated for 2 days, then drunk
Number
Name
100
Bottles
100
Caps
100
Water
Material
Process
Mass (kg)
End of life
PET
Molding
0.04
Recycle
Polyprop
Molding
0.001
Recycle
1.0
Transport
Stage 1
14 tonne truck
550 km
Use - refrigeration
Fossil to electric
M. F. Ashby, 2011
0.12 kW
2 days
24 hrs/day
The output: drink container

400
The audit reveals

the most energy
and carbon
intensive steps
Energy (MJ)
300
200
100
End of life
0
Material Manufacture Transport
-100
Use
and allows rapid

What if
100% virgin PET

with recycling
-200
12
10
Carbon (kg)
8
6
4
2
End of life
0
-2
-4
100% virgin PET

with recycling
Use
PET
Glass ?
-6
M. F. Ashby, 2011
Change the materials

1 litre glass bottle with aluminum cap
Glass moulded
Filled in France, transported 550 km to UK
Refrigerated for 2 days, then drunk
Number
Name
Material
Process
Mass (kg)
End of life
100
Bottles
Soda
glass
PET
Glass
mold
Molding
0.45
0.04
Recycle
100
Caps
Aluminum
Polyprop
Rolling
Molding
0.002
0.001
Recycle
100
Water
1.0
Transport
Stage 1
14 tonne truck
550 km
Use - refrigeration
Fossil to electric
M. F. Ashby, 2011
0.12 kW
2 days
24 hrs/day
Glass bottle replacing PET

Change
of scale
600
200
400
100
End of life
0
-100
End of life
0
-200
100% virgin PET

with recycling
Use
100% virgin glass

with recycling
-400
12
Change
of scale
10
60
50
40
6
4
2
End of life
0
Carbon (kg)
30
20
10
End of life
0
Use
Use
-10
-2
-4
200
Use
-200
Carbon (kg)
800
300
Energy (MJ)
Energy (MJ)
400
100% virgin PET

with recycling
-6
M. F. Ashby, 2011
-20
-30
100% virgin glass

with recycling
400
300
300
200
200
100
-100
Carbon (kg)
End of life
Energy (MJ)
400
100
0
Use
-100
100% virgin PET

with recycling
-200
-200
12
12
10
10
6
4
2
End of life
0
-2
-4
100% virgin PET

with recycling
-6
M. F. Ashby, 2011
Use
Carbon (kg)
Energy (MJ)
Use recycled PET instead of virgin?
Use
End of life
100% recycled PET

with recycling
6
4
2
0
Use
End of life
-2
-4
100% recycled PET

with recycling
-6
Is it practical to use recycled PET?
M. F. Ashby, 2011
400
300
300
200
200
100
-100
Carbon (kg)
End of life
Energy (MJ)
400
100
-100
100% virgin PET

with recycling
-200
-200
12
12
10
10
6
4
2
End of life
0
Use
100% virgin PET

with combustion
6
4
2
0
Use
Use
End of life
-2
-2
-4
End of life
Use
Carbon (kg)
Energy (MJ)
Combust instead of recycle
100% virgin PET

with recycling
-6
M. F. Ashby, 2011
-4
-6
100% virgin PET

with combustion
Ship by air freight, refrigerate 10 days

1000
400
Change
of scale
300
800
Disposal
0
-100
Use
400
200
-200
100% virgin PET

with truck transport
-200
-400
12
60
Change
of scale
8
6
4
2
Disposal
0
Use
-2
-4
100% virgin PET

with truck transport
-6
M. F. Ashby, 2011
Disposal
0
Material Manufacture Transpt
10
Carbon (kg)
Energy (MJ)
100
Carbon (kg)
Energy (MJ)
600
200
Use
100% virgin PET

with air freight
50
40
30
20
10
Disposal
0
Material Manufacture Transpt
Use
-10
-20
100% virgin PET

with air freight
-30
Teaching with the CES Eco-audit tool

Introductory level teaching
Overview of the life cycle

Shown how Eco Audit Tool works
Pre-loaded projects
Pre-loaded in CES Edu 2011

Bottled mineral water.prd
Hair dryer.prd
Electric kettle.prd
Which life phase dominates?
Portable space heater.prd
What could you do about it?
Family car.prd
Self-made projects
Wind turbine.prd
Students can explore change of
Material
Recycle content
Transport mode
Transport distance
Use pattern
Electric energy mix
End of life
M. F. Ashby, 2011
Jug kettle
Bill of materials and processes
2 kW jug kettle
Made SE Asia
Air freight to UK
Life: 3 years
Transport
12,000 km, air freight
250 km 14 tonne truck
M. F. Ashby, 2011
Use
6 minutes per day
300 days per year
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 make hot water on the fly only as much as needed
M. F. Ashby, 2011
The advanced Audit tool: EcoSelector
Add record
Eco Audit
Same as the
simple model
Synthesizer
Options.
^ 1. Material, manufacture and end of life

1
Component 1
Cast iron
30%
2.4
Casting
Fine machining
10%
Recycle
95%
Joining and finishing
v 2. Transport
Component 1
Painting
0.55
m2
Component 1
Welding
0.7
Choose joining
(adhesives, fastners,
welding)
v 3. Use
v 4. Report
and finishing
(painting, plating,
powder coating)
?
M. F. Ashby, 2011
Machining,
grinding, %
removed
% recovered
at end of life
Set
parameters
For advanced teaching the Enhanced
Eco Audit Tool is available in the Eco
Design Edition of CES EduPack
So what?
CES has two tools-sets to help explore the materials dimension of
environmental design
Tool 1. Eco-audits allows students to implement quick, approximate
portraits of energy / CO2 character of products.
Tool 2. Selection strategies allows selection to re-design products to meet
eco-criteria, using systematic methods
They allow fast audits and systematic materials selection for redesign
M. F. Ashby, 2011
Lecture Unit Series

These PowerPoint lecture-units are on the Teaching Resource Website
Each frame of each unit has explanatory notes. You see them by opening the
PowerPoint slide in Notes view (View Notes pages) or by clicking this icon in the
bottom toolbar of PowerPoint
M. F. Ashby, 2011
Also Available for Sustainability

On the topics of:
Eco Design & Eco Audits

Low Carbon Power Systems
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
http://teaching.grantadesign.com/open/eco.htm
M. F. Ashby, 2011
Reproduction
Author
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Attribution-NonCommercial-ShareAlike 3.0 Unported
License.
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University of Cambridge, Granta Design Ltd.
www.grantadesign.com/education
www.eng.cam.ac.uk
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credited on any reproductions. You cannot use this resource
for any commercial purpose.
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We try hard to make sure these resources are of a high quality. If you have any suggestions for improvements, please contact us
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M. F. Ashby, 2011
Grantas 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 23 lecture units created by Mike Ashby.
The website also contains resources donated by faculty at the 800+ universities and colleges worldwide using
Grantas CES EduPack.
The teaching resource website contains both resources that require the use of CES EduPack and those that dont.
Some of the resources, like this one, are open access.
M. F. Ashby, 2011

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Unit 12.

Material consumption and life-cycle

LCA - problems and solutions

Eco-audits and the audit tool

Strategy for materials selection

The product life-cycle

Emissions and waste

Life cycle assessment (LCA)

Typical LCA output

How can a designer used these data?

Design guidance vs. product assessment

Eco-audit for design

1 resource energy (oil equivalent)

1 emission CO2 equivalent

C02 equiv (kg)

This is the life-energy and life-CO2

These are potential benefits

(as prescribed in ISO 14040 and PAS 2050)

(could be recovered at end of life)

Eco-aware design: the strategy (1)

Eco-aware design: the strategy (2)

The CES Eco-audit tool

Unit transport energies

End of life choice

Typical record showing eco-properties

The simple Audit tool: Levels 1, 2 and 3

Choose Choose end-ofprocess

Material and process energy / CO2

Table of transport types:

Use phase static mode

Energy input and output

Fossil fuel to electric

Total energy and CO2 for use

Energy conversion path

Bottled water (100 units)

The output: drink container

The audit reveals

and allows rapid

100% virgin PET

100% virgin PET

Change the materials

Glass bottle replacing PET

100% virgin PET

100% virgin glass

100% virgin PET

100% virgin glass

Material Manufacture Transport

100% virgin PET

100% virgin PET

Use recycled PET instead of virgin?

100% recycled PET

100% recycled PET

Is it practical to use recycled PET?

Material Manufacture Transport

Material Manufacture Transport

100% virgin PET

100% virgin PET

Combust instead of recycle

100% virgin PET

100% virgin PET

Ship by air freight, refrigerate 10 days

100% virgin PET

100% virgin PET