Sustainable Manufacturing Key Concepts Overview 1
Agenda Agenda Introduction Sustainability Core Concepts Water Air Solids Toxicity Energy Sustainability in Practice 2
Agenda Agenda Introduction Sustainability Core Concepts Water Air Solids Toxicity Energy Sustainability in Practice 3
Agenda Agenda Introduction Sustainability Core Concepts Water Air Solids Toxicity Energy Sustainability in Practice 4
What does being Green mean to you? 5
Sustainability Meeting the needs of the present without compromising the ability of future generations to meet their own needs. 6
Current Industrial Cycle: Linear 7
Sustainable Industrial Model: Nature s Cycle 8
Unsustainable Consumption World Population hit 7 Billion on 3/12/12 Up to 5 times the Earth s resources would be required if U.S. consumption was copied by the rest of the world. Source: United Nations Environment Program, UN Global Compact and Utopies, 2005 also, World Resources Institute (WRI)/Earthtrends, 2008 Version 1.0 2014 Purdue Research Foundation 9
The Consequences 10
Sustainability Core Concepts 1. Environmental WASTE Categories 2. 4R WASTE Hierarchy 3. WASTE Inputs & Outputs 4. Sustainability Triple Bottom Line 11
Environmental WASTE Categories Water Air Solids Toxicity (Chemicals) Energy 12
4R WASTE Hierarchy Most desirable Refuse Reduce Reuse 4Rs Recycle Energy Recovery Least desirable Disposal Version 1.0 2014 Purdue Research Foundation 13
Sustainability Global Impact 14
4R WASTE Hierarchy Most desirable Refuse Reduce Reuse 4Rs Recycle Energy Recovery Least desirable Disposal Version 1.0 2014 Purdue Research Foundation 15
Sustainability Triple Bottom Line Profit (Economic) Improves efficiency & lowers costs Reduces regulatory compliance costs Creates revenue enhancement opportunities Planet (Environmental) Reduces demand for resources and energy from nature Reduces waste to nature Planet People (Social) More resources and energy become available for others Closing the loop (cradle-to-cradle) generates new jobs Version 1.0 2014 Purdue Research Foundation 16
Green is Lean Lean Thinking core concept: Eliminate waste! Sustainability core concept: Eliminate Environmental W.A.S.T.E.! Water Air Solids Toxicity (Chemicals) Energy Version 1.0 2014 Purdue Research Foundation 17
Green Fast Facts Recycling one aluminum can saves enough electricity to power your TV for 3 hours 18
Agenda Agenda Introduction Sustainability Core Concepts Water Air Water Air Solids Toxicity (Chemicals) Energy Solids Toxicity Energy Sustainability in Practice 19
Sustainable Water Management 2 Concerns with Water: Quantity Quality 20
Water Scarcity Source: International Water Management Institute 21
Point Source & Nonpoint Source Pollution 22
Business Case Planet Water-related costs rising Water-related business risks escalating Energy costs to heat/cool, treat, and transport are rising 23
4R WASTE Hierarchy -- WATER Most desirable Refuse Reduce Reuse 4Rs Refuse (don t use) Least desirable Recycle Energy Recovery Disposal Reduce (conservation) Reuse/Recover/Recirculate (divert, don t discharge) Recycle (reuse after processing or treatment) 24
Agenda Agenda Introduction Sustainability Core Concepts Water Air Solids Water Air Solids Toxicity (Chemicals) Energy Toxicity Energy Sustainability in Practice 25
Air Pollution Source: www.epa.gov 26
Climate Change Version 1.0 2014 Purdue Research Foundation Photos source: www.epa.gov/climatechange/ 27
Historical data CO 2 & Temperature 28
Current State CO2 Graph from NASA (National Aeronautics and Space Administration) website: climate.nasa.gov/causes Current CO2 data from CO2now.org Version 1.0 2014 Purdue Research Foundation 29
Future State CO2 www.epa.gov/climatechange/ Source: Intergovernmental Panel on Climate Change (IPCC) Current CO2 data from CO2now.org Version 1.0 2014 Purdue Research Foundation 30
4R WASTE Hierarchy -- AIR Most desirable Refuse Reduce Reuse 4Rs Recycle Refuse (don t use) Least desirable Reduce (quantity and toxicity) Energy Recovery Disposal Reuse/Recover (divert, don t discharge) Recycle (reuse after processing or treatment) Version 1.0 2014 Purdue Research Foundation 31
Agenda Agenda Introduction Water Air Solids Toxicity (Chemicals) Energy Sustainability Core Concepts Water Air Solids Toxicity Energy Sustainability in Practice 32
Zero Landfill A Worthwhile Goal 100% of the waste output is going somewhere other than a landfill Pursuing waste prevention, reuse, repair, recycling and composting Selling valuable by-products 33
Solid Waste Streams Paper Glass Metal Plastic Electronics Organic Construction/ Demolition Household Hazardous (paint, used oil, batteries, etc.) Special/Universal Mixed Residue? X Mixed Materials Version 1.0 2014 Purdue Research Foundation 34
Paper Recycling Recycling one ton of paper: Saves enough energy to power the average American home for 6 months Saves 7,000 gallons of water Saves 3.3 cubic yards of landfill space Reduces greenhouse gas emissions by one ton Source: www.epa.gov Version 1.0 2014 Purdue Research Foundation 35
Life Cycle of an Aluminum Can 36
E-Waste Americans discard 300 to 400 million electronic items per year About 25% recycled E-waste represents 2% of America's trash in landfills, but 70% of overall toxic waste Major source of toxins (lead, mercury, cadmium) and carcinogens (PCBs) For more information on ecycling: http://www.epa.gov/epawaste/conserve/materials/ecycling/index.htm 37
4R WASTE Hierarchy -- SOLIDS Most desirable Refuse Reduce Reuse 4Rs Refuse (don t use) Least desirable Recycle Energy Recovery Disposal Reduce (lightweighting, errorproofing) Reuse (packaging reuse, waste exchange) Recycle (waste collection, separation at the source) Version 1.0 2014 Purdue Research Foundation 38
Great Pacific Garbage Patch www.youtube.com/watch?v=d7vhrmsnrfa www.youtube.com/watch?v=y5y1w5xduie&feature=player_embedded Version 1.0 2014 Purdue Research Foundation 39
Review 40
Agenda Agenda Introduction Sustainability Core Concepts Water Air Solids Toxicity (Chemicals) Energy Water Air Solids Toxicity Energy Sustainability in Practice 41
Green Chemistry Philosophy Design products and processes to reduce use and generation of hazardous substances Use safe, environment-benign substances, including solvents 42
Drivers for Change 43
Design for Environment (DfE) Resource Concept Design Procurement Transport Manufacture Transport Extraction Consumer/ End-user Use Transport Disposal The MOST significant impact can be made during DESIGN! Version 1.0 2014 Purdue Research Foundation 44
4R WASTE Hierarchy -- TOXICITY Refuse Reduce Reuse 4Rs Reclaim Refuse (don t use) Energy Recovery Disposal Reduce (quantity and toxicity) Reuse/Recover (recirculation, energy recovery) Reclaim/Recycle (Solvent/chemical reclamation) Version 1.0 2014 Purdue Research Foundation 45
Agenda Agenda Introduction Sustainability Core Concepts Water Water Air Solids Toxicity (Chemicals) Energy Air Solids Toxicity Energy Sustainability in Practice 46
Increasing Energy Demand 800 700 600 500 400 300 200 100 0 World Energy Consumption (1990 to 2035) 1990 2000 2008 2015 2020 2025 2030 2035 World Total (Quadrillion Btu) Source: Energy Information Administration (EIA), International Energy Outlook 2011 (September, 2011 Release) 47
U.S. Energy Consumption U.S. Energy Consumption by Energy Source, 2012 Source: Energy Information Administration (EIA), Annual Energy Review 2013 Version 1.0 2014 Purdue Research Foundation 48
Impact of Unsustainable Energy Use Worldwide military engagement Greenhouse gases Habitat destruction Water pollution Air pollution Solid waste generation http://www.ted.com/ 49
ENERGY Opportunities Nutshell Leaks Compressed Air, Steam, Doors, Windows Insulation Building, HVAC, Steam Pipes, H2O Heater/Pipes Maintenance Motors, Compressed Air, Steam, HVAC, Lighting Turning things off/down Equipment, Lights, HVAC, etc. Most desirable Least desirable Lighting Over-illumination, Technology, Layout Refuse Reduce Reuse Recycle Energy Recovery Disposal 4Rs Version 1.0 2014 Purdue Research Foundation 50
Green Fast Facts The U.S. could eliminate greenhouse gas emissions equal to 800,000 cars if each household replaced just one incandescent bulb with a CFL bulb If everyone converted ALL their lighting to CFLs, we could close 90 standard-sized power plants. Source: www.doe.gov Version 1.0 2014 Purdue Research Foundation 51
Taking It Home Energy Low-Cost ways to save energy & money at home: Turn things off (refuse!) Install programmable thermostat Insulate Seal leaks (doors, windows) Install CFL/LED bulbs Look online for more ideas and details!!!! Version 1.0 2014 Purdue Research Foundation 52
Agenda Agenda Water Air Solids Toxicity (Chemicals) Energy Introduction Sustainability Core Concepts Water Air Solids Toxicity Energy Sustainability in Practice 53
Green Business All the Rage 54
Bottom Line Impact Reduce Costs Inputs Planet Water -- Water supply, infrastructure Air -- Air handling infrastructure Solids -- Direct & indirect material, storage, transport Toxicity -- Chemicals, storage, transport Energy -- Electricity, Natural Gas, Petroleum 55
Bottom Line Impact Reduce Costs Outputs Planet Water -- Wastewater treatment and disposal, permitting Air -- Emission reduction, permitting, fees/fines Solids -- Waste handling and disposal Toxicity -- Hazardous waste handling /disposal, liability Energy -- Waste heat recovery 56
Bottom Line Impact Increase Revenue New products / services New markets for existing products / services Planet Product differentiation in existing markets Higher price points Market positioning Byproduct markets Company image & good will New business models 57
W.A.S.T.E. Stream Mapping Terry the Talking Truck Production Line Injection Molding Painting Drying Plastics, Inc. Paint & Coatings, Inc. Assembly Metals, Inc. Metal Forming Metal Plating Drying Packaging Chemicals, Inc Electronics, Inc. Warehouse Other Stuff, Inc. T2Toys Toy Stores Shipping Version 1.0 2014 Purdue Research Foundation 58
Waste Stream Map Raw Materials Electricity Water Waste Air Emissions Solid Waste Toxic Waste Energy Waste Assembly lbs/yr kwh/yr Gal/yr lbs/yr lbs/yr lbs/yr MMBtu/ yr Version 1.0 2014 Purdue Research Foundation 59
Apply the 4Rs to the W.A.S.T.E. Most desirable Refuse Reduce Reuse 4Rs Recycle Energy Recovery Disposal Least desirable Water Air Solids Toxicity Energy 60
THE END Water Air Solids Toxicity (Chemicals) Energy Version 1.0 2014 Purdue Research Foundation 61