Manufacturing and the Manufacturing and the Manufacturing and the Manufacturing and the Environment 2.83/2.813 Environment 2.83/2.813 Environment 2.83/2.813 Environment 2.83/2.813 Tim Gutowski, gutowski@mit.edu
2.83 / 2.813 Addresses • Environmental issues – energy, carbon, toxics, materials use, … • Engineering – Design, Manufacturing and Life Cycle Analysis, Thermodynamics, Material Flows • Other Disciplines – economics, chemistry, industrial ecology, archeology, climatology,
Manufacturing • Value Adding – Jobs, Value Creation, Standard of Living • Long Reach – Design Decisions control material and energy flows, Supple Chain, Services • Shadow Side – Environmental Footprint – “Excess” Consumption
If today is a typical day If today is a typical day If today is a typical day If today is a typical day on planet Earth, on planet Earth, on planet Earth, on planet Earth, We will lose: 116 square miles of rainforest 72 square miles to encroaching deserts, 40 to 100 species. We will add: 250,000 more people on this planet, 2,700 tons of chlorofluorocarbons, and 18,000,000 tons of carbon to the atmosphere. after David Orr
Sustainable Development "...development that meets the needs of the present without compromising the ability of future generations to meet their own needs." Dr. Gro Harlem Brundtland former PM of Norway, chairwomen of UN commission, “Our Common Future” UN, “Brundtland Report”
Today Today Today Today • Administrative stuff • The mfg problem • Course outline • The BIG issues
Please fill out card • Name • email • year (e.g. G2 or U4) • course / program • Identify two environmental problems that concern you
World Population http://www.census.gov/ipc/www/p opclockworld.html
Some questions Some questions Some questions Some questions • how do you know that this is a problem? • where did you get your information? • do you agree with your class mates? • what is behind each of these problems?
Baloney Detection Kit Baloney Detection Kit Baloney Detection Kit Baloney Detection Kit • How reliable are the sources of this claim? Is there reason to believe that they might have an agenda to pursue in this case? • Have the claims been verified by other sources? What data are presented in support of this opinion? • What position does the majority of the scientific community hold in this issue? • How does this claim fit with what we know about how the world works? Is this a reasonable assertion or does it contradict established theories? • Are the arguments balanced and logical? Have proponents of a particular position considered alternate points of view or only selected supportive evidence for their particular beliefs? • What do you know about the sources of funding for a particular position? Are they financed by groups with partisan goals? • Where was evidence for competing theories published? Has it undergone impartial peer review or it is only in proprietary publication? after Carl Sagan
Environmental Challenges Environmental Challenges Environmental Challenges Environmental Challenges Environmental Concerns Linkage to Manufacturing Processes 1. Global climate change Greenhouse gas (GHG) emissions from direct and indirect energy use, land fill gases, etc. 2. Human organism damage Emission of toxins, carcinogens, etc. including use of heavy metals, acids, solvents, coal burning… 3. Water availability and quality Water usage and discharges e.g. cooling and cleaning use in particular 4. Depletion of fossil fuel resources Electricity and direct fossil fuel usage e.g. power and heating requirements, reducing agents 5. Loss of biodiversity Land use, water usage, acid deposition, thermal pollution 6. Stratospheric ozone depletion Emissions of CFCs, HCFCs, halons, nitrous oxides e.g. cooling requirements, refrigerants, cleaning methods, use of fluorine compounds 7. Land use patterns Land appropriated for mining, growing of bio-materials, manufacturing, waste disposal 8. Depletion of non-fossil fuel resources Materials usage and waste 9. Acid disposition Sulfur and NO x emissions from smelting and fossil fuels, acid leaching and cleaning from Graedel and Allenby 2005
Manufacturing ’ s Profile Manufacturing ’ s Profile Manufacturing ’ s Profile Manufacturing ’ s Profile • Energy • Waste • Toxic Materials • Mixing and Diluting • Regulations
Energy Flow in the U.S. Energy Flow in the U.S. Energy Flow in the U.S. Energy Flow in the U.S. Quadrillion (10 15 )BTU’s = 1.005 EJ DOE, 2001 1 BTU = 1055 J
Waste by Sector in U.S. Waste by Sector in U.S. Waste by Sector in U.S. Waste by Sector in U.S. Medical Note: A large fraction of the total weight in the industrial categories is Coal Ash water. Dry weight of industrial wastes can be as low as 10% of the total. MSW Hazardous 2005 EPA data: Ind. ~7 G t Agricultural MSW~ 0.23 G t Oil and Gas Mining Manufacturing 0 1 2 3 4 5 6 Billion Metric Tons of Waste Generated Source: US Congress, OTA-BP-82 Major Waste Types by Weight in the United States
Total Toxic Releases by Sector Total Toxic Releases by Sector Total Toxic Releases by Sector Total Toxic Releases by Sector Off-site/Underground Injection 4,000,000,000 Land 3,500,000,000 Underground Injection 3,000,000,000 Water 2,500,000,000 Air 2,000,000,000 1,500,000,000 1,000,000,000 500,000,000 0 Mfg. Metal Coal Elec. Chem. Petrol Bulk RCRA Mining Mining Utilities Wholesale Term Solvent Recovery EPA, 1998
Mfg controls materials flows Mfg controls materials flows Mfg controls materials flows Mfg controls materials flows 100 90 80 concentration 70 Alu 60 50 Fe 40 Cu 30 20 10 0 Crust Ore Smelt Alloy Product MSW Manufacturing
Environmental Regulations ref Allen & Shonnard
Mfg Summary • Significant, often hidden shadow side – e.g. Direct and indirect energy (50%) • Significant regulation already exists • Interconnected with wealth generation • Need Incentives to be Green
“You can’t manage what you can’t measure” • Ecological Footprint • Mass Flow Analysis • Intro to Bio-Geo-Chemical Cycles • Energy/Exergy Analysis • Life Cycle Analysis
Course Outline http://web.mit.edu/2.813/www/
February February February February Monday Monday Monday Monday Wednesday Wednesday Wednesday Wednesday 6. Introduction 11. Eco-Footprint 13. Scale, Flow and Cycles (Tues) 19. Sustainability?* 20. Intro to LCA 25. Energy/Exergy 27. End-of-life March March March March 3. Visitor 5. Remanufacturing 10. Recycling 12. “ Coal ” discussion 17. Discussion 19. Quiz 1 24. (Spring Break) 26. (Spring Break) 31. LCA April April April April 2. Scale and Efficiency 7. Materials Production 9. Manufacturing 14. Manufacturing 16. Measuring Progress 21. Patriots Day 23. Visitor 28. Visitor 30. Presentations May May May May 5. Presentations 7. Field Trip 12. Review 14. Quiz 2
Grading 1. Quiz I (30%) 2. Quiz II (30%) 3. Project (30%) 4. Class Participation (10%) 100%
Reading List Books: Books: Books: Books: 1. 1. 1. 1. Freese, Freese, Freese, Freese, Barbara, 2003. Coal A Human History Coal A Human History, Penguin Books. Coal A Human History Coal A Human History 2. 2. 2. 2. Smil, Vaclav, 2006. Smil, Smil, Smil, Energy Energy Energy Energy, , Oneworld Oxford Publications. , , 3. 3. 3. 3. Hendrickson, Chris T., Lave, Hendrickson Hendrickson Hendrickson Lave, Lave, Lave, Lester B. and Matthews Matthews Matthews Matthews H. Scott, 2006. Environmental Life Cycle Assessment of Goods and Services An Input Environmental Life Cycle Assessment of Goods and Environmental Life Cycle Assessment of Goods and Environmental Life Cycle Assessment of Goods and Services An Input Services An Input Services An Input – – – – Output Approach, Resources for the Future Press. Output Approach Output Approach Output Approach See webpage for the rest…
Looking at the System • NSF panel visits Japan, Europe and the United States (52 sites) • What is “Environmentally Benign Manufacturing?” • 1999 -2001 time frame
EBM Panel in Japan Oct 23,1999
What did we learn? • There is no silver bullet • It’s the system – system boundaries – coupled phenomena – disaggregate the problem
System Boundaries: LCA Mining Materials Mfg Distribution Use Disposition & & & & & & & & & & & & m m m m m m m m m m m m 0 0 0 0 0 0 8 8 8 8 8 8 & & & & & & m & m & m & m & m & m & m p o m p o m p o m p o m p o m p o p i p i p i p i p i p i k k k k k k k k k k k k Recycle, Remanufacture, Resell, Reuse
Light Bulbs and Mercury Light Bulbs and Mercury Light Bulbs and Mercury Light Bulbs and Mercury Allen and Shonnard
Light Bulbs and Mercury Light Bulbs and Mercury Light Bulbs and Mercury Light Bulbs and Mercury Allen and Shonnard
Paradoxes and boundaries • Interdependence: complex systems and human behavior – recycling grinding swarf…..
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