Sustainable Design in Engineering

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Sustainable Design in Engineering

• ECE 0909.403 / 0909.504.02 - Lecture 13
• Why the lights went out? 14 August 2003
• Lab 1 Sustainable Design Challenge
• LCAs of TV and an Electro-hydraulic Valve
• 19 November 2003
• Dr. Peter Mark Jansson PP PE

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Aims

• 14 August 2003 Elaboration
• Lab 1 Sustainable Design Challenge
• LCA of the Bang Olufsen LX5500 Television
• Scope definition of product system
• Environmental exchanges / Impact assessment
• Environmental diagnosis for the LX5500 TV
• LCA of an EHC Valve
• Scope definition of product system
• Environmental exchanges / Impact assessment

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14 August 2003

• https//reports.energy.gov/
• U.S. Canada Power Systems Outage Task Force
  Causes of the August 14th Blackout

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Reliable transmission

• 7 principles
• 1. Continuously balance generation / demand
• 2. Balance reactive power to maintain voltage
• 3. Monitor flows to not exceed thermal limits
• 4. Keep system in stable condition
• 5. Keep system in reliable condition (n-1)
• 6. Plan, design and maintain to operate reliably
• 7. Prepare for emergencies

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Sequence unchanged

• Assessment
• Inadequate System Observation Loss of System
  Control and Data Acquisition
• Outages due to inadequate tree trimming
• Harding Chamberlain 345 kV 43.5 loaded
• Hanna-Juniper 345kv 87.5 loaded
• Star South 345kV 93.2 of emergency rating
• Once this situation occurred FE needed to
  voluntarily reduce load so as not to impact
  remaining system, due to their unawareness of the
  n-1 contingency breach they did not take this
  critical action

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Lab 1 Sustainable Design Challenge

• Rowan University Plans to spend 27.3 Million on
  townhouses in Rowan Woods to create 464
  additional beds on campus for housing residential
  students.
• You have 1 hour in your lab to determine the key
  2-5 Sustainable Design project investments you
  propose to President Farish and the Board of
  Trustees costing less than 30 million that would
  make Rowan a premier sustainable university
  campus.
• Maximize the environmental savings to the
  university (CO2 reduction, BTUs, etc.) while
  attempting to create the strongest business case
  for your proposals (I.e., shortest paybacks, rate
  of returns, etc,)
• Use sustainable technologies you have learned
  about

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Sustainable Technologies to Consider

• Energy Efficiency investments
• HVAC technologies (geothermal, etc.)
• Lighting retrofits, controls, etc.
• Increased efficiency in building envelopes
• Renewable Energy Investments
• Wind, Solar (PV, thermal, etc.), Biomass,
• Cogeneration Systems
• Gas turbines
• Fuel Cells,

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Background Campus Data

• Annual Energy Usage
• Electric 24,011,814 kWh 2,173,028
• Cogeneration Plant 8,137,700 kWh 737,920
• Gas - 2,116,799
• Campus Size 1,904,337 sq.ft
• gt 40 buildings, gt 5 large parking lots
• Average Use for Comparable Universities 18.9 kWh
• Rowan Usage per sq.ft 16.9 kWh (electricity
  only)

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Constraints

• Identify and list all key assumptions
• Use web or me for assistance for any renewable
  energy resource estimates
• All capital investments must be made within a 50
  miles radius of campus
• Present each project in detail
• Estimated cost, units, energy impact, env.
  benefits, payback estimate
• You will have 4-5 minutes to sell your overall
  plan and discuss its benefits

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Projects will be peer graded

• You will each assign a priority to one anothers
  conceptual designs
• Our 30 million will be spent on the top 3-5
  project proposal elements

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The LCA Process
Impact Assessment
Goal
Scope
Inventory
Environmental. Assessment (E.A.) of
References Environmental Diagnosis E.A. of
Concepts E.A. of Details
The Product System Materials Manufacture Use
Disposal
Environmental Exchanges Inputs (Energy
Materials) Outputs (Air, Water Waste) Work
Environment
Impact Potentials Resource Consumption (Energy
Materials) Environmental Impacts (Global
Warming, Acidification, Ozone, etc.) Impact on
Work Environment
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LX5500

• Chosen as Reference Product
• TV believed to have greatest impact
• Greatest environmental FOCUS in BO
• Representative model (flagship)
• High degree of complexity

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Functional Unit

• Reception of TV programs for 6 hours per day with
  18 hours standby for 10 years for a 28 color
  television
• Secondary qualities
• BASIC FEATURES Picture quality (colors and
  sharpness), sound quality, number of channels,
  etc.
• OPTIONS remote control, teletext, decoders,
  connecting with external speaker system.

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MECO Scope def.

• Extent of product system included based upon the
  MECO analysis
• Materials with few exceptions all components are
  included in the LCA (mfg proc. for gt 90)
• 24.5 kg picture tube (21.8 glass, 1.5 Fe, .5 Cu)
• 11.0 kg plastic (casing, rear cover, speakers)
• 2.9 kg contrast screen (2.75 glass, .15 Fe)
• 0.96 kg speakers (.43 Fe, .53 magnets)

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MECO Materials (cont.)

• 3.15 kg electronics of which
• 2.0 kg plastic
• 0.5 kg Fe (iron)
• 0.42 kg Cu
• 0.10 kg Al
• 0.12 kg Pb (lead)
• 0.23 kg Aluminum for edging
• Remaining 10 of weight, estimate of scarce
  resource consumption was undertaken

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MECO (continued)

• Chemicals ancillary substances for the
  manufacturing process at Bang Olufsen (i.e.,
  lubricants and cleaning chemicals) were included
  and emissions (incomplete in the tracking of
  chemical production all the way back to nature)
• Others working environment impacts were omitted
  from the LCA since many large components were
  manufactured by subcontractors, service and
  repairs not included

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Material Production (Gram)

• Crude Oil ME, Africa, North Sea, EE, US
• Natural Gas North Sea
• Coal Europe, US
• Plastic Italy (ABS), Germany (PE, PVC)
• Chemicals Netherlands, France, Germany
• Metals ores from all over the world (ship and
  rail) and processed in Europe

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Manufacturing Process

• Mostly from subcontractors
• Germany and France
• Few components in-house
• Printed circuit boards at Skive, DK plant
• Highly uniform production, assembly
• Total consumption of materials
• Emissions and total waste of factory
• Transport included for 90 of TV (weight)

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Other

• Wastewater treatment plant output tested 9 times
  per year
• Rejection rate faulty components discarded at
  each step in manufacturing process, raw materials
  consumed gt raw materials in final TVs shipped
• Overhead Allocation of HVAC, lighting, canteen
  costs from factory and administrative facilities
  distributed to each television produced on weight
  basis of years sales

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Use Process

• Used mostly in European Union (Germany, France,
  Denmark, Sweden, Finland, rest of EU) with 10
  sent to rest of world
• Country of use is important for 4 reasons
• Transport (by trucks to central and dealers)
• Use patterns vary between nations
• Electricity impacts vary
• Disposal varies environmental impact

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Use (continued)

• In winter months, unit contributes to heating of
  homes, so energy consumption in the homes is
  reduced. (i.e., quantity of energy replaced was
  subtracted from televisions consumption)
• Impact on cooling was not considered
• Electricity for use was for country of use

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Disposal Process

• Assumed
• no recycling of TVs today
• 70 of TVs are dumped (15 km transport)
• 30 are assumed incinerated (30 km)

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Resource Consumption

• Television 42.7 kg
• Resources to produce materials 80 kg
• Manufacturing 23 kg
• Use 480 kg
• Transport 3.5 kg
• TOTAL 630 kg

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Emissions to Air

• CO2 (1.3 tonnes)
• Primarily from energy systems (81 in use)
• Use 75-80 of NOx, 92 SO2
• Transport 44 of CO and 54 of Pb
• Disposal most of Dioxins emitted

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Emissions to Water

• Some heavy metal emissions in production and
  extraction of raw materials

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Waste

• Largest in use phase (coal residue)
• Television itself in dump, or quartz slag during
  incineration

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Energy Profiles

• Energy accounts for a large proportion of
  resource consumption and emissions
• 78 of energy consumption in Use Phase 90 while
  TV is on and 10 while TV is in Standby mode
• 22 of total energy consumption is raw material
  extraction, and material production.
• Designer has most impact on materials selected
  (i.e., energy needed to extract, manufacture
  materials, etc.)
• Calorific value only 11 (recycle vs. incinerate)

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Impact Assessment

• Most significant resources copper and natural
  gas
• Most significant environmental impact global
  warming, acidification, radioactive waste, slag
  and ashes and bulk waste
• Most significant working environment impacts not
  estimated based upon scope

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Sources of Impact

• The picture tube 20 of oil and 50 of natural
  gas resources are used in its production
• Electricity 82 of slag and ashes, 68 of bulk
  waste and 83 of global warming

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Environmental Diagnosis

• To identify the potentials for improvement in the
  product so that, together with the environmental
  assessment of the reference product, a basis can
  be formed for points of focus

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How?

• Simulate various theoretical changes in the
  product or product system
• Or
• Generate information on known technologies that
  are potentials for improvement

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Simulation

• Following the MECO principle
• Materials disposal
• 100 recycle of metals
• Wood case instead of plastic
• Energy use
• Standby energy is halved

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Simulation

• Chemicals consumption
• Casing not painted
• Others
• Change lifetime increase

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Findings from Simulation

• Consumption of Cu reduced 90 and Al 75 by
  recycling scenario
• Wood casing reduces oil and gas use by 5, global
  warming by 2 (Casing only product system impacts
  are gtgt)
• Not painting reduces ozone impact by 72

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Efficiency

• 5, 10 and 30 increases in efficiency were
  simulated
• Overall 10 reductions in electricity yield 8
  reduction in global warming impact potential
• 7 reductions achieved in Avant model
• 30 unlikely without technology change

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Sources of Improvement

• Picture tube (Large contributor to use,
  materials production and waste phases) LCD
  alternative 50 less energy, laser scanning or
  plasma displays
• Electricity Use part is forgetting to turn off
  or as background entertainment
• Install sensor (motion or presence) control
• Remote control notification (TV off in 100 min.)
• Separate Tube from sound and control tube only

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Potentials Identified

• PC boards in Electronics Package thick film
  technology from Danfoss
• Increases electronics lifespan
• Reduces scarce metal use (70 Sn, 65 Pb, 25
  Cu)
• Standby energy 10 of use stage energy
• Construct TV and VCR in single unit and combine
  standby energy requirement

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Potentials (continued)

• Number of materials reduce total
• recovery is difficult due to two types of
  plastic (PS and ABS), trim metals, internal
  metals
• use one type of plastic, omit items (trim)
• Casing, rear cover and front panel painting
  reduces recyclability
• avoid painting or use different paints
• change materials (wood, etc.)

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Material Points of Focus

• copper in deflection coils, replaced with other
  material or make it easier to separate from tube
• zinc in picture tube spacers can be made of
  steel, cast iron or recycled aluminum
• primary aluminum profiles replaced with
  recycled Al, make case not needing profiles in
  design, make Al more easily removed

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Env. Specification for TV

• Materials choose materials that enable
  recycling, construct for ease of dismantling,
  substitute primary aluminum
• Energy reduce power use during operation and
  standby
• Chemicals avoid toxic substances, dont paint
  with substances that reduce recyclability

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LCA of Danfoss PVEH

• Proportional Valve Electric High Performance
  the electro-hydraulic activation unit for
  hydraulic valves, cranes, excavators, trucks and
  many other hydraulic applications

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PVEH

• Chosen as Reference Product
• Danfoss developing a new generation of EHV units
• Complex product
• Mechanical, electronic, hydraulic parts

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Functional Unit

• Regulation of one hydraulic proportional valve in
  a hydraulic system for 5 years
• Secondary qualities
• Inbuilt error monitoring, fast reaction time with
  an inductive feedback transducer monitoring the
  main sliding valves position in the hydraulic
  valve, little hysteresis (i.e., very high
  precision)

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Resource Consumption

• PVEH 1 kg
• Resources to produce materials 3 kg
• Manufacturing 4 kg
• Use 12 kg
• Transport 0.14 kg
• TOTAL 20 kg

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Energy Profiles

• Energy accounts for a large proportion of
  resource consumption and emissions
• Energy in use stage is highest
• Energy in manufacture is second highest (86 of
  this is from overheads for manufacturing)

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Environmental Diagnosis

• To identify the potentials for improvement in the
  product so that, together with the environmental
  assessment of the reference product, a basis can
  be formed for points of focus

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Summary of Simulations

• Thick film technology increases life span of PVEH
  (fewer soldered joints)
• Use of materials is decreased by increased life
  span
• TF technology also decreases consumption rate for
  scarce metals
• Removal of PC boards prior to shredding enhances
  material separation

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New Product Design

• Thick film instead of conventional fiber glass
  reinforced epoxy laminate technology increases
  life from 5 to 8 years reducing all metal use
• Thick film technology requires less energy in
  manufacturing
• Tantalum capacitors are replaced by ceramic caps
• Change in yoke design reduces Fe by 30