Unit Process Life Cycle Inventories Sutardja Dai Hall, Berkeley 23/05/2012 1
Unit Process Life Cycle Inventories 1. Welcome and Introduction Prof. Michael Overcash 2
Overview Welcome and Introduction CO 2 PE! UPLCI Methodology DIN 8580 Process Taxonomy Experiences with screening UPLCI Hands-on session Integration within LCI-databases Future action items and Discussion 3
Manufacturing Sector Background Tens to hundreds of thousands of manufacturing plants (known as transformational steps because these convert materials and chemicals into macro-shape products) Output of families of products (simple to complex) Stakeholder expectations Company has invested in a life cycle understanding of their products Can provide some form of quantitative environmental footprint of their products The unit process life cycle inventory (UPLCI) concept has been developed to meet these large global needs of manufacturers and stakeholders UPLCI is a building block concept to estimate energy and material use at the machine level of a manufacturing plant For most manufacturing facilities transforming materials or chemicals into industrial or consumer products there are about 120 separate unit processes that are used 4
Unit Process Life Cycle Inventories 2. CO 2 PE!-UPLCI Methodology Prof. Joost Duflou 5
Methodology for Systematic Analysis and Improvement of Manufacturing Unit Process Life Cycle Inventory Machine Tool Level Life Cycle Inventory data Sub-Process Level Optimisation Measures & Eco-Design Guidelines Kellens, K., Dewulf, W., Overcash, M., Hauschild, M., Duflou, J.R. (2012), Methodology for systematic analysis and improvement of manufacturing unit process life cycle inventory (UPLCI), Int. Journal of Life Cycle Assessment, Vol. 17/1:69-78. 6
Methodology for Systematic Analysis and Improvement of Manufacturing Unit Process Life Cycle Inventory Functional Unit: Quantifies the qualitative and quantitative aspects of the (main) function(s) of the manufacturing unit process along the questions what, how much, how well, and for how long Reference Flow: 1 second of processing time for a specified load level of a unit manufacturing process for a specified material based on a working scheme of 2000 hours/year. The system boundaries include the actual machining modes, as well as the allocated part of the non-productive modes. Guidance for new ISO standard 14955 (Environmental evaluation of machine tools) 7
Critical comparison of methods Duflou, J.R., Kellens, K., Renaldi, Guo, Y., Dewulf, W. (2012), Critical comparison of methods to determine the energy input for discrete manufacturing processes, CIRP Annals, Vol. 61/1. 8
Unit Process Life Cycle Inventories 2b. Case Study - In-Depth Approach Electrical Discharge Machining Karel Kellens 9
Case study (In-Depth Approach): Electrical Discharge Machining Time Study Die Sinking Supporting Mode 25% Operational Mode 66% Standby Mode 9% standby mode: e.g. process waiting for operator supporting tasks mode: e.g. workpiece supporting mode: e.g. clamping, tool change, tank filling, calibration Kellens, K., Renaldi, Dewulf, W., Duflou, J.R. (2011), Preliminary Environmental Assessment of Electrical Discharge Machining, 18 th CIRP LCE2011 Conference, Braunschweig. operational mode: e.g. material removal: roughing and finishing operations 10
Power [kw] Power [kw] Case study: Electrical Discharge Machining Die Sinking EDM Power Study Wire EDM 4 3,5 3 2,5 2 1,5 1 0,5 0 Other Fans & Lightning Drives Generator Pump 5 4,5 4 3,5 3 2,5 2 1,5 1 0,5 0 Other Fans Drives Generator Filling pump Filtration pump Supporting pump High pressure pump Pumps are the dominant electrical energy consumers. Die Sinking EDM: up to 72%, Wire EDM: up to 65% 11
Case study: Electrical Discharge Machining Consumable Study Die Sinking EDM Wire EDM Micro EDM Compressed Air 1 l/min (6 bar) 1 l/min (6 bar) 4,8 l/min (6 bar) Dielectric Hydrocarbon Oil 10 l / week Replacement each year De-ionized water 10 l / week Replacement each year Hydrocarbon Oil 0,45 l / week Replacement each year Dielectric filters Replacement every 200 hours De-ionization Resin / Replacement each year / Cooling water (10-15 C) 6 l/min 6 l/min 2 l/min Air filters Replacement every three months Others Lubrication Oil 0.5 1 l / Year Grease: 250 g/year Wire Guides Grease: 100 g/year Wire electrode for shaping Note: Based on a working scheme of 2000 hours/year (250 days with 1 shift) + Removed workpiece material (W) as well as the tool electrode wear (T) 12
Case study: Electrical Discharge Machining Emission Study Based on PhD-Thesis S. Evertz (2003 RWTH Aachen): Electrical Discharge Machining: exposure assessment using emission and immission based monitoring 13
Case study: Electrical Discharge Machining Impact Assessment Distribution of the environmental impact during 1 hour of EDM roughing (copper electrode, hard metal workpiece) Total of ~ 450 mpts 14
Case study: Electrical Discharge Machining Impact Assessment Distribution of the environmental impact during 1 hour of EDM roughing (copper electrode, hard metal workpiece) Compressed Air 0,1% Lubrication 0,1% Energy Consumption Process Cooling 19,4% Process Emissions 0,0% Energy Consumption Exhaust System 3,9% Dielectric (Production + EOL) 23,1% Energy Consumption EDM Process 47,3% Removed Workpiece Material 1,0% Electrode Material 5,1% Electrical Energy and Dielectric main contributors to environmental impact. 15
Process Models: Framework Kellens, K., Renaldi, Dewulf, W., Duflou, J.R. (2012), Environmental impact modeling of discrete part manufacturing processes, 19 th CIRP LCE2012 Conference, Berkeley. 16
Process Models: Case study of Laser Cutting 17
Unit Process Life Cycle Inventories 3. Process Taxonomy Prof. Joost Duflou 1
Process Taxonomy: Extended DIN 8580 2. Forming 3. Separating 4. Joining 1. Primary Shaping DIN 8580 5. Coating & Finishing 7. Auxiliary Processes 6. Changing Material Properties Complete taxonomy overview available in workshop handout 19
SCREENING Current Coverage of Process Taxonomy Interested to join the Initiative and cover one or more of the (missing) processes, don t hesitate to contact us and / or place your sticker on this poster. Barbara Linke Process Name Indicate the process name here 20
Unit Process Life Cycle Inventories 4. Experiences with screening UPLCI studies Prof. Michael Overcash 21
Screening UPLCI: Experiences and Future Research Manufacturing as Transformational Stages Chemical and material building with transformations to macro shapes 22
Screening UPLCI: Examples of the information demand government (GSA, 2010) customers (Wal-Mart, 2011) business-to-business participants (Environmental Product Declarations, UL, 2011) product associations (NSF/ANSI, 2009) 23
Screening UPLCI: Goals uplci blocks that are non-complex and transparent. a fully populated 120 unit process database. a rapid means of evaluating and supporting decisions for energy improvement of advanced materials, processes, and technology in macroshape building industry. add material efficiency, with science-based methods that show direct energy benefits over the whole supply chain, an important innovation. 24
Material Supply Chains look like this: PET Ethylene glycol Ethylene oxide Ethylene Naphtha Crude Oil 0.132 0.044 0.032 0.024 0.02 0.03 Oxygen Air (untreated) 0.023 0.033 Water for rxn Water (untreated) 0.012 0.012 p-benzenedicarboxylic acid Acetic acid Carbon monoxide Carbon dioxide Natural gas Natural gas (unprocessed) 0.113 0.017 0.009 0.004 0.001 0.001 Nitrogen from air Air (untreated) 0.002 0.002 Oxygen from air Air (untreated) 0.001 0.001 Water for rxn Water (untreated) 0.001 0.001 Natural gas Natural gas (unprocessed) 0.003 0.003 Water for rxn Water (untreated) 0.001 0.001 Methanol Natural gas Natural gas (unprocessed) 0.009 0.006 0.006 Water for rxn Water (untreated) 0.004 0.004 Oxygen from air Air (untreated) 0.058 0.058 p-xylene Toluene Naphtha Crude Oil 0.073 0.074 0.074 0.077 25
Life cycle of manufacture pump ENERGY OR CHEMICAL LOSS PRODUCTION ENERGY AMOUNT UNITS 930 MJ/PUMP TRANSPORT ENERGY 36 MJ/PUMP AIR EMISSIONS 58 KG/PUMP WATER EMISSIONS 0.01 KG/PUMP SOLID WASTES 9.3 KG/PUMP TOTAL CHEMICAL LOSSES 67 KG/PUMP 26
Screening UPLCI: Creating UPLCI building blocks High production system basis. 90:10 rule is critical. All unit process blocks need reasonably close similarity in order to construct higher order manufacturing systems LEGO Principle. Generic UPLCI data build from a common framework for each unit process. Connect transformation LCI to supply chain LCI. Allocation is an infrequent issue for these transformational plants. 27
UPLCI data matrix of 7 Stages of unit process operation power time material loss method of calculation full mode operation X1 Y1 Z directly product related partial full mode or idle X2 Y2 indirectly product related standby X3 Y3 production related 28
Screening UPLCI: Current Status UplcI Identification MR1 MR2 MR3 MR4 MR5 MR6 MR7 MR8 J1 J2 J3 MC1 MC2 HT1 SF1 Drilling Shearing Milling Turning Punching Reaming Grinding Boring Gas metal arc welding Submerged arc welding Friction stir welding Brakeforming Injection molding annealing Coolant application 29
Screening UPLCI: Lessons Learned 1) The results are just estimates that are representative (90:10 rule is simple, but hard to transition) 2) A knowledgeable person can create a uplci in about 1-2 weeks of concentrated work 3) Partial and standby time components of the 7 matrix are first riority 4) Transparency is a major benefit in use by others as it establishes what was assumed and how used 30
Screening UPLCI Path Forward 31
Building from UPLCI database Overhead (HVAC and Lighting) for Building Casting Spray Painting Inspection Rahimifard, 2010 integrating process and non-process energies each unit process has an machine area footprint 32
Building from UPLCI database Five plant studies, 25 machines For each machine obtain area then use regression to get full allocated area 33
Research in connecting UPLCIs Each unit process changes the properties of the workpiece that affect the cumulative energy shape mass surface properties Each block is energy and mass loss per unit of unit process output (so for each step there is a basis change) This concept of connection is a major part of a user interface 34
Natural Resource Energy, MJ/output workpiece Life cycle energy profile of transformations by unit processes to make a product 35 30 25 20 15 10 5 0 0 1 2 3 4 5 6 7 8 CTG Level 35
Test Bed Research The behavior of 3-10 unit processes in sequence or recycle loops is more than the characteristic of the single UPLCI Studies of aggregate and individual UPLCI field data (energy and mass utilization) test the system behavior Known as verification and improvement 36
Longer term UPLCI research for transformation manufacturing plants or corporate developments Alternative manufacturing plant sequences Process and non-process energy estimations Coupling with materials and chemicals supply chain User interfaces Integrating with use and end-of-life phases (impact of recycling and reuse) Simulation Optimization Comparative analysis of new technology 37
Unit Process Life Cycle Inventories 4b. Panel Discussion Dr. Barbara Linke, Prof. Fu Zhao Prof. Karl Haapala 38
Unit Process Life Cycle Inventories 4c. Industrial Collaboration Society of Manufacturing Engineers Kathy Looman, Prof. Michael Overcash 39
Goals 1. Introduce and facilitate use in manufacturing plants to UPLCI tools that estimate energy and mass utilization 2. Utilize industrial expertise to review and support unit process studies (in-depth and screening) 3. Test the UPLCI tools on sequences of machines in high production facilities 40
Industrial Technical Communities Plastics, Composites & Coatings Automated Manufacturing & Assembly Industrial Laser Forming and Fabricating Product & Process Design and Management Rapid Technologies and Additive Manufacturing Machining and Material Removal 41
Path Forward Technical paper to all members Planning for webinar On screening UPLCI On in-depth UPLCI Pont of contact in each of the technical groups Review UPLCI studies Concept of test beds 42
Unit Process Life Cycle Inventories 5. Coffee Break 43
Unit Process Life Cycle Inventories 6. Hands-on Session Karel Kellens and Renaldi 44
Hands-on session Group Work: Small groups of 4/5 persons based on taxonomy Discussion on processes within process taxonomy Select 1 to 3 processes within your taxonomy category Process inputs/outputs? Production modes? Process parameters? 3 questions in preparation of the discussion session (last agenda point) What are the challenges of both CO 2 PE-UPLCI approaches? How can industry be actively involved in this effort? Which funding initiatives could be useful in support of collaboration between partners within the CO 2 PE!-UPLCI effort? 45
Unit Process Life Cycle Inventories 7. Integration within LCI databases Prof. Wim Dewulf Wim.dewulf@groept.be 46
Tool for Life Cycle Inventory (LCI) data submission 47
Unit Process Life Cycle Inventories 7. Integration within LCI databases Data Input 48
Process identification DIN 8580 Taxonomy Meta data Sub-studies 49
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Production modes ISO 14955 ISO 14955 Machine functions 51
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Time Study Machine functions 53
Power study Production modes Machine functions 54
Consumables study Production modes External LCI data 55
Emissions study Production modes External LCI data 56
Waste streams to technosphere Production modes External LCI data 57
Unit Process Life Cycle Inventories 7. Integration within LCI databases Data export 58
Tool output CO 2 PE! UPLCI Database Single Unit Process LCI records ISO 14955 Report Aggregated records EcoSpold data format Exchanges: overview of the flows from eco- as well as techno sphere to the unit process and vice versa. Allocation: where relevant, procedures and allocation factors for exchanges of multi functional unit processes should be described. Process information: description of the reference unit (functional unit), time period, geography, technology and dataset information. Modeling and Validation: describes the representativeness of the data set, sources (e.g. literature) and validations (e.g. reviewers) Administrative Information: documents involved persons, originator and the published source of the dataset. Source: http://www.ecoinvent.org 59
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EcoSpoldAccess Excel Ecospold V1 61
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Dissemination channels targeted Single Unit Process LCI records CO 2 PE! UPLCI Database 64
Unit Process Life Cycle Inventories 8. Future action items and Discussion Prof. John Sutherland, Prof. Janet Twomey Prof. Jacqueline Isaacs 65
Future Action and Discussion Feedback on the major concepts, improvements, and potentially missing elements of the two CO 2 PE-UPLCI efforts. Industrial participation concepts and collaboration. How specifically will the audience participate and what funding initiatives might arise to help with the CO 2 PE-UPLCI effort. 66
Discussion Remarks? Suggestions? Comments? Questions? Thank you for your attention! 67