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Manufacturing and the Manufacturing and the Manufacturing and the Manufacturing and the Environment 2.83/2.813Environment 2.83/2.813Environment 2.83/2.813Environment 2.83/2.813Tim Gutowski, gutowski@mit.edu
Alissa Jones, ajones@mit.edu
Young Song, ysong@mit.edu
Let’s change rooms
New Room
35-520
Given Lounge
35-5201-246
Mass Ave
Vassar St
2.83 / 2.813 Addresses
• Environmental issues
– energy, carbon, toxics, materials, …
• Engineering
– LCA, Thermodynamics, environmental
accounting
• Other Disciplines
– climatology, chemistry, archeology, industrial
ecology, ecological economics,….
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
Sustainable Development
"...development that
meets the needs of
the present without
compromising the
ability of future
generations to meet
their own needs."
UN, “Brundtland Report”
Dr. Gro Harlem Brundtland
former PM of Norway,
chairwomen of UN commission,
“Our Common Future”
Today
• Administrative Stuff
– Please Fill Out Cards
– Course Outline
– Grading
– Project
– Readings…
• Mfg & System Issues
– mfg profile
– paradoxes
– IPAT eq
– strategies
Please fill out card
• Name
• year (e.g. G2 or U4)
• course / program
• List 2 environmental problems that are
important to you
World Population
http://www.census.gov/ipc/www/p
opclockworld.html
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• 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
Sulfur and NOxemissions from smelting and fossil fuels, acid
leaching and cleaning
9. Acid disposition
Materials usage and waste8. Depletion of non-fossil fuel resources
Land appropriated for mining, growing of bio-materials,
manufacturing, waste disposal
7. Land use patterns
Emissions of CFCs, HCFCs, halons, nitrous oxides e.g. cooling
requirements, refrigerants, cleaning methods, use of
fluorine compounds
6. Stratospheric ozone depletion
Land use, water usage, acid deposition, thermal pollution5. Loss of biodiversity
Electricity and direct fossil fuel usage e.g. power and heating
requirements, reducing agents
4. Depletion of fossil fuel resources
Water usage and discharges e.g. cooling and cleaning use in
particular
3. Water availability and quality
Emission of toxins, carcinogens, etc. including use of heavy
metals, acids, solvents, coal burning…
2. Human organism damage
Greenhouse gas (GHG) emissions from direct and indirect
energy use, land fill gases, etc.
1. Global climate change
Linkage to Manufacturing ProcessesEnvironmental Concerns
from Graedel and Allenby 2005
Manufacturing’s Profile
• Energy
• Waste
• Toxic Materials
• Mixing and Diluting
• Regulations
Energy Flow in the U.S.
Quadrillion (1015)BTU’s = 1.005 EJ
1 BTU = 1055 J DOE, 2001
Waste by Sector in U.S.
0 1 2 3 4 5 6
ManufacturingMining
Oil and Gas
Agricultural
Hazardous
MSW
Coal Ash
Medical
Billion Metric Tons of Waste GeneratedSource: US Congress, OTA-BP-82
Note: A large fraction of the total
weight in the industrial categories is
water. Dry weight of industrial wastes
can be as low as 10% of the total.
Major Waste Types by Weight in the United States
2005 EPA data:
Ind. ~7 G t
MSW~ 0.23 G t
Total Toxic Releases by Sector
0
500,000,000
1,000,000,000
1,500,000,000
2,000,000,000
2,500,000,000
3,000,000,000
3,500,000,000
4,000,000,000Off-site/Underground Injection
Land
Underground Injection
Water
Air
Mfg. Metal Coal Elec. Chem. Petrol Bulk RCRA
Mining Mining Utilities Wholesale Term Solvent Recovery
EPA, 1998
0
10
20
30
40
50
60
70
80
90
100
Crust Ore Smelt Alloy Product MSW
Alu
Fe
Cu
Most Importantly: Mfg controls materials flows
Manufacturing
concentration
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
• A Major Challenge
Analysis Tools for Accounting
• 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 Monday Wednesday 7. Introduction
12. Eco-Footprint 14. Sustainability?
20. Scale, Flow and Cycles** 21. Exergy Accounting
26. Intro to LCA 28. Materials Production
March
5. Cutler Cleveland @ 12 noon 7. Mfg Processes
12. Mfg Processes 14. “Coal” discussion
19. Discussion 21. Quiz 1
26. (Spring Break) 28. (Spring Break)
April 2. LCA 4. Scale and Efficiency
9. Material Recycling 11. Product Recycling
16. (Patriots Day Holiday) 18. Product Reuse
23. Photovoltaics (TB) 25. Nanomfg (JI)
30. Presentations
May 2. Presentations
7. Project Follow-up 9. Field Trip
14. Review 16. 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 HistoryCoal A Human HistoryCoal A Human HistoryCoal A Human History, Penguin Books. 2.2.2.2. Smil, Smil, Smil, Smil, Vaclav, 2006. EnergyEnergyEnergyEnergy,,,, Onewor ld Oxford Publications.
3.3.3.3. HendricksonHendricksonHendricksonHendrickson, Chr is T ., Lave,Lave,Lave,Lave, Lester B. and MatthewsMatthewsMatthewsMatthews H. Scott, 2006. Environmental Life Cycle Assessment of Goods andEnvironmental Life Cycle Assessment of Goods andEnvironmental Life Cycle Assessment of Goods andEnvironmental Life Cycle Assessment of Goods and Services An Input Services An Input Services An Input Services An Input – Output ApproachOutput ApproachOutput ApproachOutput Approach, Resources for the Future Press.
See webpage for the rest…
Zero Order Model of the System
Production Consumption
Earth
Class ProjectClass Focus
Project: Life Style Analysis…
Diet
Electronics
…more
Housing
Travel
Nursing home patient
StudentRockStar
CEO
Today
• Administrative Stuff
– Please Fill Out Cards
– Course Outline
– Grading
– Project
– Readings…
• Mfg & System Issues
– mfg profile
– paradoxes
– IPAT eq
– strategies
2. Looking at the System
• EBM Panel and the win-win scenario
• Paradoxes and boundaries
• Disaggregating the problem
– The IPAT Equation
• Solutions
– Free Market Solutions
– Government Intervention
EBM Panel in Japan Oct 23,1999
What did we learn?
• There is no silver bullet
• It’s the system
complex, interconnected, non-linear and
including human behavior
Paradoxes and boundaries
• Interdependence: complex systems and
human behavior
– telephone and car trips
– email and paper
– efficiency and conservation
– consumption and happiness
Designing in/out the Human Factor
Recyclable
process waste
contaminated
with trash
Human behavior plays a key role at every level
from Bert Bras
System boundaries
You must consider not only the product,
but also how it is used.
Mining Primary Mfg Distribution Use Disposition
0m& 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, Reuse
Life Cycle Framework
Light Bulbs and MercuryLight Bulbs and MercuryLight Bulbs and MercuryLight Bulbs and Mercury
Allen and Shonnard
Light Bulbs and MercuryLight Bulbs and MercuryLight Bulbs and MercuryLight Bulbs and Mercury
Allen and Shonnard
Disaggregating the Problem
Services & Goods
Impact
Person
Services & Goods PopulationImpact ××=
T A P I ××=
for infinitesimals
T
T
A
A
P
P
I
I ∆+
∆+
∆=
∆
Population Growth
World Population
http://www.census.gov/ipc/www/p
opclockworld.html
RIN P0 ROUT ][
][
emigrationnimmigratio
deathbirthR
−+
−=∆
PRdt
dP⋅∆=
Population Dynamics
2006t
P
World
6.5 B
1965
3.2 B
dtRP
dP⋅∆=
tR
oePP ⋅∆=
n
o iPP )1( +=
in the discrete form…
Currently i ≈1%
We are adding 70-80 M people/yr
Add one Germany or 2X Canada each year
for infinitesimals
T
T
A
A
P
P
I
I ∆+
∆+
∆=
∆
Affluence = GWP per captia
Affluence and GDP, GWP
• GDP = Gross Domestic Product
• GWP = Gross World Product
• GWP = market value of all goods and
services produced for a year
GWP, i ≈ 5% for 2004, 2005
To improve, we want…
0 <∆
+∆
+∆
=∆
T
T
A
A
P
P
I
I
1%+4%-5%=0Based onglobalestimates…
We must improve our environmental performance ongoods and services by 5% a year just to stay even.
F=P(1+i)n
5.4%/yr
How hard is it to improve
by 5% per year?
Examples of improvements
• Pig Iron (energy 1800–1984) 1.1%
• Aluminum (energy 1900–1987) 1.0%
• Air Travel (energy 1971–1997) 3.7%
• Nitrogen Fertilizer (energy 1930-1989) 4.4%
• Machine tools (time 1900-2000) 5.4%
• Moore’s Law (2x in 2 yrs) 41%
• Kyoto Protocol ~0.4%
Yes 5%/yr is possible, but…
• it will require incentives
• we want more than 5%
• will 5% improvement in efficiency result is
a 5% reduction in scale?
Engineering Strategies
source sink
recirculation
Engineering Strategies
1. Reduction at Sink
• pollution prevention
2. Reduction at Source
• substitution
• efficiency
3. Recirculation
• reuse, remfg, recycle
Incentives??
Bigger Picture Solutions
• make people richer !?
– lower birth rates, more concern, more consumption
• free market solutions
– charge for “externalities”
– market failures e.g. eco-system services
• government intervention
– ecological taxes
– efficiency standards
– cap and trade programs
see www.Harvard.edu
Fertility and Affluence
What is Needed
• System Knowledge
• Analysis Tools
• New Technologies
• Policy Intervention
Please Do Your Ecological
Footprint for Next Time
http://www.rprogress.org/
World Population
http://www.census.gov/ipc/www/p
opclockworld.html
Remember Room 35-520Next Time
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