Unit Process Life Cycle Inventory - A Project in Environmentally Benign Design and Manufacturing (EBDM)

1. Unit Process Life Cycle Inventory - A Project in Environmentally Benign Design and Manufacturing (EBDM) Professor Jacqueline Isaacs, Northeastern University Professor Janey Twomey, Wichita State University Professor Michael Overcash, Wichita State University Cambridge, MA August 29, 2009

2. Presentation in Three Parts • History of events – Jackie Isaacs • Implementation – Jan Twomey • Strategic Issues – Michael Overcash

3. History: Pathway to 2009 Professor Jackie Isaacs Northeastern University

4. Isaacs Mfg /LCA Research Focus • Two Areas: • Powder metallurgy and responsible nanomanufacturing • Process-based cost models built to simulate engineering economics of unit processes in part fabrication • Use materials from cost models as input for LCA models • Issues with impact assessment…

5. Enviro & Economic Uncertainties Regulatory Issues in MA Social & Ethical Issues Responsible Nanomanufacturing • Determine best safety practices and screening methods for nanomaterials as well as impact of possible releases EHS Assessment, Tox Screening& EOL Impacts • Perform Life Cycle Assessment (LCA) of developing processes / products and evaluate tradeoffs for EHS (environmental health and safety) with costs with UML with Benneyan • Promote informed policymaking with Bosso NSF NIRT • Advocate productive public discourse with Sandler NSF NIRT Integrated Systems Approach Required for Appropriate and Efficient Commercialization

6. Goal & Scope Inventory Analysis Life Cycle Assessment Framework InventoryAnalysis Interpretation Impact Assessment ImpactAssessment ISO 2005 Interpretation

7. Raw Material • Labor • Energy • Equipment • Building • Overhead • Tools • Maintenance Process Based Cost Modeling Input Variables Intermediate Variables Output Variables # of lines of Arc vessels Total time to make required batches Production Vol g/yr Variable Costs Working hours per year Square feet space input production Building space per vessel No of batches based on prod vol. Labor hours for input production Vessel size Yield Fixed Costs Catalyst composition Moles of helium used per batch Cost of helium over entire annual production Cost of catalyst Catalyst weight per batch Cost of catalyst over entire annual production Cost of helium

8. Cost Modeling /Simulation to Seek EHS Tradeoffs Monte Carlo Simulations Cost Modeling Scenarios Ok, Benneyan, Isaacs Journal of Industrial Ecology Special Nanotechnology Issue 2008 Worker Protection Worker Protection Worker Protection Healy, Dahlben, Isaacs Journal of Industrial Ecology Special Nanotechnology Issue 2008 Analyses provide useful guidance for decisionmakers Distinctions among scenarios would allow more informed decisions…

9. In the Meantime… Pathway to Present • Goals: • Create a tool set for the efficient lci of manufactured products based on the individual unit processes that sum to a product lci • Stimulate a large community to both develop and use the uplci tools on diverse manufactured products • Begin with low complexity products as examples

10. Background • Origins were process/product improvement = EBDM • Funding leadership – U.S. National Science Foundation (Dr. Delcie Durham) • Continual international participation

11. Evolution of EBDM Events • 2001: WTEC Study on EBM • 2001: Transport. Indstr Workshop Yipsilanti, MI • 2003: EBDM Workshop (Sustainable Mfg I) Birmingham, AL • 2003: Green Engineering, Sandestin, FL • 2004: Sustainable Mfg II: Global Conference on Sustainable Product Design and LCE, Berlin, Germany • 2005: Sustainable Mfg III, Shanghai, China • 2006: EBDM for Sustainable Economic Competitiveness, Arlington VA • 2006: Sustainable Mfg IV, São Carlos, Brazil • 2007: Sustainable Mfg V, Rochester, NY

12. Unit Process LCI Project • Built on earlier uplci studies by • J. Allen and M. Overcash, June, 2001 • C. Murphy, et. al., ES&T 2003 vol.37, p.5373 • 2003 Alabama Breakout Session Concept • Concept conveyed to Alting and Seliger • 2006 Brazil Conference • concept identified again • international solicitation for participant • No non-U.S. volunteers

13. EBDM UPLCI Team (Alphabetical Order) • Bert Bras, Georgia Tech • Andres Clarens, Virginia Tech • Delcie Durham, University of South Florida • Tim Gutowski, MIT • Jackie Isaacs, Northeastern University • Leon McGinnis, Georgia Tech • Cynthia Murphy, University of Texas, Austin • Michael Overcash, Wichita State University • Matthew Realff, Georgia Tech • Steve Skerlos, University of Michigan • Jan Twomey, Wichita State University

14. Continued Planning… • EBDM Team meetings at Northeastern University to discuss concepts and methodology • October 2007 • February 2008 • Draft Generic uplci methodology finalized • February 5, 2008 • EBDM Team votes on name….. • “unit process life cycle inventory” (uplci) • October, 2008

15. Implementation of UPLCI Methodology Professor Janet Twomey Wichita State University

16. Implementation of UPLCI Methodology • U.S. Dept. of Energy interest in wind energy • Primarily nonfuel electricity where mot of the life cycle inventory is in manufacturing • Focus on green manufacturing tools as a means to improve wind energy • Needed life cycle information that focused on many individual decision possibilities and not just wind versus coal data

17. First steps • Selected unit processes in cluster, such as materials removal • Learned how to combine or how to search for data from industry, published articles, handbooks, other books, etc. - Helps when one group will do many uplci • Began to examine a non-complex, but widely used product, the brace for aircraft members, called a clip

18. Amada Brake Press Cut Profile Form Bend Finn Power Turret Punch A Generic Sheet Metal Clip Multi-CAM Router Validation

19. Taxonomy of process http://cratel.wichita.edu/uplci • Website intended for collaborative effort • Operates somewhat like a Wiki • Anyone can download content • you have to have permission to add content Instructions Log in to add comments, content

20. Expanded taxonomy Content is in Word format Can be down loaded by anyone New or updated content can be added with author and date only by users with log in

21. Strategic and Specific Issues for UPLCI Professor Michael Overcash Wichita State University

22. Background from Chemical Manufacturing Life Cycle Inventory Tools, 1990 - present • Heuristics – 20 – 25 • Used to create process flow diagrams of entire plant and then lci outputs • 700+ chemicals • Major lessons learned • Transparency is vital • 90:10 rule is the focus • Creates substantial power to lower cost and expand user community • Not just inputs and energy, but decision-making

23. Manufacturing Unit Process Life Cycle Inventories • Manufacturing plants represent the transition and use of materials (metals/polymers) and chemicals into a final product • Uplci thus links the chemical lci world to the product manufacturing world • Goal to encourage development of other uplci using similar format, so that additive property is achieved

24. Draft Generic Format: Includes Seven Sections (I to VII)(User is not expert in unit process, but is interested in product) • Description of unit process operation (such as general discussion of milling machine) • Picture of machine and process • High production plant • Representative unit process • Mass input-output for process • functional unit floor-to floor of workpiece (focus is on lci of product not plant) • not limited to mass I/O of workpiece, but focused on machine

25. Draft Generic Format: Section III • Description of the overall sequence by which a workpiece arrives, is operated on, and departs from the unit process • Basic energy offloading and unloading (standby mode) • Idle energy of tool positioning (partial power mode) • Tip energy of operation (full power mode)

26. Draft Generic Format: Sections IV-VII • List of parameters affecting energy or mass loss (critical phase that differentiates life cycle use from unit process design intentions) • Reduction of parameters to only major variables • Allows user to identify how to refine • Detailed explanation and equations for linking major variables to the energy and mass loss equations (allows users to follow clearly and apply to all other applications of the uplci) • Strengthens understanding that a representative case is used • Example application fully worked out to show mass loss and energy estimates for use of the uplci(every variable and equation used in the example should be in section V. ) • References

27. Lessons Learned with uplci • Important concept is to remember the systems goal of product life cycle • Even low complexity products may be 10 – 100 uplci • Specialized resources can dive deeply on other issues • Keep user perspective • Focus is on a specific product, like a gearbox or ceiling fan • Have default data in uplci to allow use

28. Path Forward • Learn how to reduce to most important variables, but show others • Provides data beyond CO2 • Many of the important data are not as easily available and so need transparent approximation concepts are important • Idle time (partial standby mode) • Reviewing stage = new territory • Industrial context • Not easy to adopt idea of review outside very unique user case • Process flow diagrams (approximation)

29. Important Path Forward Issues • Uplci principles and harmonization • Encouragement of others to write these documents (multiple per unit process can be good, but needs to be consolidated) • Taxonomy • Is substitution of similar processes reasonable? • Allow objectives of research on improvement?

31. Discussion Questions to Address… • Can your research effort add to • The database of unit processes? • The review and refinement of these uplci? • How does your research effort intersect the development of the CO2PE/uplci project (such as process improvement)?