engineering our way to sustainable economic...
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Industrial Sustainability: performance & potential
Sustainable Thermal Energy Management in the Process Industries International Conference
Steve Evans Director of the Centre for Industrial Sustainability, University of Cambridge
Director EPSRC Centre for Innovative Manufacturing in Industrial Sustainability
Director, Centre for Sustainable Engineering
Partner, Riversimple
Previously: Special Adviser, House of Lords
Sustainability Champion, Minister for Skills
Running
There is no one in the factory at this time
How many consecutive straight lines are needed to connect all nine dots?
How many consecutive straight lines are needed to connect all nine dots?
How many consecutive straight lines are needed to connect all nine dots?
450ppmv CO2e
greenhouse gas emission pathways
50% chance of 2°C
(kindly taken from) Kevin Anderson
Tyndall Centre
Universities of Manchester & East Anglia
Alice Bows Sustainable Consumption Institute (SCI)
University of Manchester
June 2009
Destruction of vast majority of coral reefs
Billion++ people suffer water stress & risk coastal flooding
30% species extinction
Cereal production reduces in low latitudes
Land becomes a carbon source
Risk triggering tipping points
(e.g. albedo, permafrost, etc)
Impacts around 2°C
Total greenhouse gas emission pathways
Year
2000 2020 2040 2060 2080 2100
Em
issio
ns o
f gre
enhouse g
ases (
GtC
O2e
)
0
20
40
60
80
Year
2000 2020 2040 2060 2080 2100
Em
issio
ns o
f gre
enhouse g
ases (
GtC
O2e
)
0
20
40
60
80
Year
2000 2020 2040 2060 2080 2100
Em
issio
ns o
f gre
enhouse g
ases (
GtC
O2e
)
0
20
40
60
80
Low DL
Low DH
Medium DL
Medium DH
High DL
High DH
2015 peak 2020 peak 2025 peak
(Anderson & Bows. 2008 Philosophical Transactions A of the Royal Society. 366. pp.3863-3882)
The challenge by 2050:
To double output, While emitting 80% less GHGs & halving resource use
The challenge requires radically new approaches we term, Industrial Sustainability, which implies nothing less than a new industrial revolution.
Case: Martin-Baker Engineering
Hazardous Waste Reduction
6973
7673
33
25 26 26
0
10
20
30
40
50
60
70
80
No
. o
f T
an
kers
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Year
Total No. of Tankers to Remove Harzadous Waste From MBA
Hazardous Waste Reduction
Total disposal cost for alkaline & acid liquid waste
£59,965.95
£23,604.87
£64,429.01£65,332.24
£12,852.37£15,664.77
£11,187.67
£0.00
£10,000.00
£20,000.00
£30,000.00
£40,000.00
£50,000.00
£60,000.00
£70,000.00
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Year
Co
st(
£s
)
Water Reduction
TOTAL FACTORY & FINISHING DEPARTMENT YEARLY WATER USAGE
60586830
8030
15969
19935
21084
64736000
0
5000
10000
15000
20000
25000
2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Target
Main
s w
ate
r V
ol.
m3
TARGET FIGURE
After considerable research and much discussion, the decision was made to purchase a centralised Metal Working Fluid (MWF) recycling system. The type selected was the Vivex unit, supplied by Fluid Solutions Ltd.
less coolant in skips = £++ so….
Our Metal Waste & Coolant Solution
Case: Who is this?
TMM Europe Targets
1. Energy usage
2. Water usage
3. Volatile Organic Compounds (VOCs)
released from painting operations
4. Waste to landfill
5. Degree of compliance with
environmental regulations
6. Number of complaints from external
(neighbourhood) parties
Actual (2001-2006)
1. - 44%
2. - 37%
3. - 32%
4. - 99%
5. All plants ISO14001
Aim:-
Zero
Emissions
Integrated Approach
Ultimate ECO
Factory
Risk
Reduction
Air Land Water Zero Non
Compliance
& Complaint
Energy
Toyota Motor Europe
Green, Lean and Clean
Towards the Ultimate
ECO Factory
Organisational Learning Problem Solving, Root Cause Analysis, Kaizen (Continuous Improvement) and Yokoten (Sharing)
Zero CO2
Zero Landfill
Zero Incineration
Renewable Energy Recover Rainwater
VOC Free
ECO Audit
Substance of
Concern Free
Prior Prevention ISO 14001
Risk Audit
Toyota Production System
Plant Minimum Requirements
Internal Control Limits
Control Criteria
Toyota Environment
Management System
Apply 5R’s Hierarchy Refine, Reduce, Reuse. Recycle, Recovery to Energy
New Plant Design Criteria
Optimised Environmental Performance
No 1 Performance by 2010 T O Y O T AE M S
Law
Adherence
Compliance/
no-complaint
World No.1
Regional No.1
EnvironmentalRisk
Prior
Prevention
Improvementof
Minimizationof
EnvironmentalPerformance
T O Y O T AE M S
Law
Adherence
Compliance/
no-complaint
Compliance/
no-complaint
World No.1
Regional No.1
EnvironmentalRisk
Prior
Prevention
Improvementof
Minimizationof
EnvironmentalPerformance
S.B. Hope 1st August 2006
Toyota Motor Europe
Environment and Facility
Plant Engineering Division
Key Production Environmental Priorities
Energy use (CO2)
Waste generated
Waste sent to landfill
Water consumption
Volatile Organic
Compound emissions
Environmental KPI Results (TMUK)
WATER
0
1
2
3
4
5
6
7
8
9
10
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Years
m3
/Ca
r
Over 75% Reduction
Water usage per vehicle (m3) ENERGY
0
1000
2000
3000
4000
5000
6000
7000
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Years
Kw
h/C
ar
Over 70% Reduction
Energy usage per vehicle (KWh)
VOLATILE ORGANIC COMPOUNDS
0
10
20
30
40
50
60
70
80
90
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Years
g/m
2
Over 70% Reduction
VOC emissions per vehicle (g/m2) WASTE
0
5
10
15
20
25
30
35
40
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Years
Kg
/Ca
r
Over 60% Reduction
Waste produced per vehicle (kg)
Examples of Leadership Energy reduction
• Employees responsible for switch off
• Energy switch observation points
• Clear instructions for switch off times
• Local ownership of energy control
Site Electrical Loading
0
2
4
6
8
10
12
14
16
06
:30
07
:00
07
:30
08
:00
08
:30
09
:00
09
:30
10
:00
10
:30
11
:00
11
:30
12
:00
12
:30
13
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13
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14
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14
:30
15
:00
15
:30
16
:00
16
:30
17
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17
:30
18
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:30
19
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19
:30
20
:00
20
:30
21
:00
21
:30
22
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22
:30
23
:00
23
:30
00
:00
00
:30
01
:00
01
:30
02
:00
02
:30
03
:00
03
:30
04
:00
04
:30
05
:00
05
:30
06
:00
Time
MW
Inter-shift shutdown focus
Day shift
(production) Night shift
(production)
Time
Burnaston Plant site electrical loading
Between shifts (no production)
M
W
Target: no production = no energy use
Oct 06
May 08
Toyota Manufacturing Europe progress
Energy in manufacturing (kWh/vehicle) • 2001 - 2006 = 44% reduction
• 2006 - on = new programmes
• 2010 = investigation of paint plant refrigeration?
• 2011 = investigation of paint drying?
When will they reach a limit?
What is that upper limit?
Root Causes: Why is the performance as it is?
Technology
Organisation
‘division of labour’
Impacts ‘externalities’
Adaptation
Stress
‘disruptions’
Multiply
‘copy prior success’
Material Efficiency realities?
Low requirement for collaboration Norm business model
Higher co-ordination demand Higher value
Eco-efficiency:
Do more with less
Increment
Eco-factory: Join the pieces
Eco-efficiency
Sustainable Industrial System:
Whole System Design
Eco-factory
Eco-efficiency
Industrial Sustainability EPSRC Centre for Innovative Manufacturing in
How to make current products in a low-carbon, resource efficient manner.
How to transform our factories and products.
Explore how the entire industrial system might change
4 universities
88+ PhDs
100+ companies
15+ projects
1st Industrial Revolution
• labour is scarce
• nature is abundant
Next Industrial Revolution
• nature is scarce
• labour is abundant
1st Industrial Revolution
• labour is scarce
• nature is abundant
Focus on labour productivity
Technology push
Sub-optimising
Next Industrial Revolution
• nature is scarce
• labour is abundant
Focus on resource productivity
Back-casting pull
Whole System Design
The Planet is finite Solar income & Ideas are abundant