Module6 Ktunotes - in Min

Green Engineering
N ES . I
KTU NOT
Dr. P.R. Sreemahadevan Pillai
To get more study materails visit www.ktunotes.in

What is Green Engineering?
 Design, discovery, and implementation
 Molecules, products, processes, systems
 Maximize Inherency
E S . I N
 Maximize mass, energy,
U N O T time, and space
efficiency K T

Goals of Principles of Green
Engineering
 Provide a framework
 Applicable
 Effective
 Appropriate
 Apply across disciplinesOTE S . I N


K T U N
Chemical, Civil, Environmental, Mechanical, Systems…
 Apply across scales of design

 Molecular architecture to construct chemical compounds
 Product architecture to create a cell phone
 Urban architecture to build a city

How were the Principles of Green
Engineering developed?
 Identify examples of successful engineering

that moves towards sustainability
 various disciplines
 various scales ES . I N
N O T
 TU
Elucidate theKunderlying principle(s)
embedded in the examples.
 See if the embedded principles are
applicable across scales and across
disciplines
 even if not generally realized

How to think about Principles of
Green Engineering?
 Not Rules, commandments, or natural laws.
 Can be viewed as performance parameters
 Need to be optimized
 Synergies ES . I N
N O T
 Trade-offs
KTU
 Need to be applied in context
 Vary with innovation, creativity
 Vary with culture, society

How to think about Principles of
Green Engineering? (cont.)
 Often synergistic with traditional design
metrics.
 Quality
 Safety
ES . I N
 Cost effective
N O T
KTU
 Moving towards sustainability is a
performance goal.

Fundamental Issues in applying the
Principles of Green Engineering
 Inherency
 Life cycle foundation across all

principles. E S . I N
N O T
KTU
 Holistic or so-called “systems
thinking” should be applied to avoid
the unintended consequence of
doing the wrong things, but doing
them very well.

Applying the Principles of Green
Engineering:
Schematic of potential benefits vs. investments
p o te n tia l re a liz e d b e n e fits
ES . I N re-define
U N O T the
problem
KT
re-engineer
the system
optimize the
existing solution
(incrementalism)
investments (i.e., time, money, resources,energy)

The 12 Principles of Green
Engineering OTES.IN
K T U N

Principle 1
 Designers need to strive to ensure that all
material and energy inputs and outputs
are as inherently non-hazardous as
possible. S.IN
O T E
K TUN

Principle 2
 It is better to prevent waste than to treat
or clean up waste after it is formed.
ES . I N
N O T
KTU

Principle 2 (cont.)
 “End of pipe” technologies
 Containment systems for storage and
disposal
ES . I N
 Expensive N O T
KTU
 Constant monitoring
 Potential to fail

Principle 3
 Separation and purification operations
should be a component of the design
framework.
ES . I N
N O T
KTU

Principle 3 (cont.)
 Up-front design allows products to self-
separate using intrinsic physical/chemical
properties such as solubility, volatility, etc.
ES . I N
N O T
KTU
The catalyst is soluble in one of the reagents and remains soluble when
the other reagent is added. As the reaction goes on, and the product
builds up, the catalyst precipitates from the mixture as oil. This oil—
liquid clathrate—remains to be an active catalyst, as the reagents are
able to penetrate into it. When all the reagents are converted into
products, the oily catalyst turns into a sticky solid, which can be easily
separated and recycled.
"A Recyclable Catalyst that Precipitates at the End of the Reaction."

Dioumaev, VK, and RM Bullock. July 31, 2003. Nature 424(6948):530-
531

Principle 4
 System components should be designed
to maximize mass, energy and temporal
efficiency.
ES . I N
N O T
KTU

Principle 4 (cont.)
 Process intensification
 Sophisticated actuator-control systems
ES . I N
N O T
KTU

Principle 5
 System components should be output
pulled rather than input pushed through
the use of energy and materials.
(Le Chatlier’s Principle) S.IN
O T E
K TUN
Le Chatelier's Principle
"If a system in equilibrium is subjected to a

stress the equilibrium will shift in the direction
which tends to relieve that stress."

Principle 5 (cont.)
 Often “drive” a reaction or transformation to
completion by adding materials or energy.
A+B C+D
ES . I N
N O T
KTU
 Similarly, a reaction can be “pulled” to
completion by removing the product without
adding materials or energy.
A+B C+D

Principle 5 (cont.)
 Just in time manufacturing
 Production is based on demand
 eliminates waste due to overproduction and lowers warehousing
costs

ES . I N
supplies are closely monitored and quickly altered to meet
changing demands N O T
 KTU
small and accurate resupply deliveries must be made just as
they are needed

Principle 6
 Embedded entropy and complexity must
be viewed as an investment when making
design choices on recycle, reuse or
beneficial disposition. S.IN
O T E
K TUN

Principle 6 (cont.)
 The amount of complexity built into a product
whether at the macro, micro, or molecular
scale is usually a function of resource
expenditures. S.IN
O T E

 K TUN
High complexity, low entropy – reuse
Lower complexity – value-conserving recycling where possible
or beneficial disposition
 Natural systems can also be recognized as
having complexity

Principle 6 (cont.)
 Case for modular, standardized, platform-

based, upgradable design

TU N O T ES . I N
K


Principle 7
 Targeted durability, not immortality,
should be a design goal.
ES . I N
N O T
KTU

Principle 7 (cont.)
 Products that last well beyond their useful
commercial life often result in environmental
problems ranging from solid waste to
persistence and bioaccumulation. N
T ES . I

T U N O
Repair and maintenance must also be
considered K
 Must balance targeted lifetime with durability
and robustness in anticipated operating
conditions.

Principle 7 (cont.)
 Biodegradable plastics
ES . I N
N O T
KTU

Principle 8
 Design for unnecessary capacity or capability
should be considered a design flaw. This
includes engineering “one size fits all”
solutions. S.IN
O T E
K TUN

Principle 8 (cont.)
 While product agility and product flexibility
can be desirable, the cost in terms of
materials and energy for unusable capacity
and capability can be high.S.IN
O T E
 UN
There is alsoKaTtendency to design for the
worst case scenario such that the same
product or process can be utilized regardless
of spatial or temporal conditions.

Principle 8 (cont.)
 A single laundry detergent
formulation that is intended to
work anywhere in the US and
must be designed to work inS . I N
the most extreme N O
hard T E
water
K T U
conditions
 Phosphates were added as builders to
remove hardness of water
 Phosphates, by their high nutrient value,
can cause eutrophication in water bodies

Principle 9
 Multi-component products should strive
for material unification to promote
disassembly and value retention.
(minimize material diversity)
S.IN
O T E
K TUN

Principle 9 (cont.)
 Selected automobile designers are reducing
the number of plastics by developing different
forms of polymers to have new material
characteristics that improveSease
. I N of
disassembly and N O T E
recyclability.
K T U
 This technology is currently applied to the
design of multilayer components, such as
door and instrument panels.

Principle 9 (cont.)
 For example, components can be produced using a
single material, such as metallocene polyolefins,
that are engineered to have the various and
necessary design properties.

S
Through the use of this monomaterial
E . I N design
N
strategy, it is no longer
U O T
necessary to disassemble
K T
the door or instrument panel for recovery and
recycling

Principle 10
 Design of processes and systems must
include integration and interconnectivity
with available energy and materials flows.
ES . I N
N O T
KTU

Principle 10 (cont.)
ES . I N
N O T
KTU

Principle 11
 Performance metrics include designing
for performance in commercial “after-life”.
ES . I N
N O T
KTU

"When we reuse our products —

much less recycle them —.Iwe N keep
our costs down O T E S
significantly," says
K T U N
Rob Fischmann, head of worldwide
recycling at Kodak. "The second-
time cost for these cameras is
essentially zero."

Principle 12
 Design should be based on renewable
and readily available inputs.
ES . I N
N O T
KTU

 With cooperative development from
Mitsui Chemicals Inc. and Cargill-Dow,
LLC, SANYO achieved the world's first
bio-plastic (polylactic acid) optical disc in
9/2003.
 Use corn as base material to derive
ES . I N
N O T
polylactic acid with its optical property and
exact structure. KTU
 Roughly 85 corn kernels is needed to
make one disc and one ear of corn to
make 10 discs. The world corn production
is about 600 million tons, less than 0.1%
is needed to make 10 billion discs
(current annual worldwide demand).

In the end, Green Engineering
Principles…
 Create a universal language between
designers at all scales leading to…
 Inherent
 Innovative
 Integrated
ES . I N

U
Interdisciplinary N O T
K T
 … systematic designs that consider
environmental, economic, and social
criteria…
 … the goal of sustainability.

Industrial Ecology
S.IN O T E
K TUN
Dr. P.R. Sreemahadevan Pillai

History of IE
ES . I N
N O T
KTU
Robert A. Frosch Nicholas E. Gallopoulus

History of IE
• A system that "would maximize the
economical use of waste materials and of
products at the ends of their lives as inputs
to other processes and industries."
.IN
T ES
KT UNO -Frosch, 1992
• Essentially mimics natural systems

Types of Industrial Ecosystems
• Local, Regional, National, Global
• Industrial Symbiosis
ES . I N
N O T
KTU Park
• The Eco-Industrial

An Eco-Industrial Park in
Devens, Massachusetts

“We should leave to the next
generation a stock of ‘quality of
life’ assets no less than those we
S . I N
T U N OTE
have inherited.”
K -Devens Enterprise Commission
- Local opinion
- Government action
View of Devens, Massachusetts
ES . I N
N O T
KTU

Major Characteristics of the
Devens Eco-Industrial Park
• Material, water, and energy flows

• Companies within close proximity
• Strong informal ties between
ES . I N
U N O T
plant managers
K T
• Minor retrofitting of existing
infrastructure
• One or more anchor tenants.

Examples of IE
Common Sense IE:
Saving resources
Recycling
Be efficient when possible
ES . I N
N O T
Why? KTU
Fewer resources consumed
 lower operational costs
Less waste/trash
 lower disposal costs

Examples
• Liberal plans
• Using renewable resources

• Wastes become N S . I N
new
OTresources
E
KTU
• Efficient production
• Long-lasting design of systems

PSU Dining Commons
• Computer software
• Batch Cooking ES . I N
N O T
KTU
• Napkins

Kalundborg, Denmark
• Industries exchange wastes
• Companies made agreements 70s – 90s
• Asnaes – Coal-fired powerN plant
T ES . I
• Statoil – Oil T
Refinery
N O
K U
• Gyproc – plasterboard company
• Novo Nordisk – biotechnology company

Coal Power Plant
Inputs: Products
•Coal • Electricity
•Surplus gas
from • Steam
ES . I N + Heat
U N O T
nearby K T • Hot Salt Water
refinery • Ash
•Cool Salt • Gypsum
Water
http://www.indigodev.com/Kal.html
Waste Gas
Coal
Power N
T
Plant ES . I
N O
KTU
Gypsum

Fuels
Petroleum Gas
Oil
Refinery
ES . I N
Steam
N O T
KTU
Sulfur

ES . I N
N O T
KTU

ES . I N
N O T
KTU

Industrial Ecology in Kalundborg
• Saves resources:
– 30% better utilization of fuel using combined
heat + power than producing separate
– Reduced oil consumptionES.IN
N O T
KTU
– 3500 less oil-burning heaters in homes
– Does not drain fresh water supplies
• New source of raw materials
– Gypsum, sulfuric acid, fertilizer, fish farm
http://www.symbiosis.dk
Lead
ES . I N
N O T
KTU

ES . I N
N O T
KTU
1989 http://print.nap.edu/pdf/0309049377/pdf_image/77.pdf
Analysis of Lead, 1989, USA
• % Lead consumed for batteries = 78%
• In lead-acid batteries 700,000 tons out
of 800,000 tons recycled, were re-
processed and reused . I N
OTE~ (87%)
T
S
U N
K
http://books.nap.edu/books/0309049377/html/77.html#pagetop
~ 360,000
~ 130,000
~ 90,000
ES . I N
N O T
KTU
Smith, Gerald. “Lead Recycling in the United States in 1998”.

~ 880,000
ES . I N
N O T
KTU
~ 1,420,000
~ 1,000,000

Lead, 1998
• % Lead consumed for batteries = 88%
• 95% recycling efficiency
ES . I N
N O T
KTU

Automobile IE
• 65% of an automobile is comprised of
iron and steel
• In 2001, 15 million tons of iron and steel
were recycled from . I N
automobiles
ES
U N O T
T
• Can be usedKto produce 48 million steel
utility poles
http://www.recycle-steel.org/cars/main.html
From the Junkyard
• Useable engines, tires, batteries, fluids,
and other parts are removed for resale
• The body is shipped to a scrap yard
• Magnets separate iron/steels
S . I N
O T E
• Scrap metal
K is
T Usent
N to steel mills
• New car bodies are made with at least
25% recycled steel
• Other parts such tires can be shredded
and reused
http://www.recycle-steel.org
ES . I N
N O T
KTU
http://www.fes.uwaterloo.ca/u/jjkay/pubs/IE/
Why Aluminum?
• Can replace steel
• Less dense than steel
• Increased fuel economy due to lighter
S . I N
automobiles UNOTE
K T
• Less emissions
• rusting

Aluminum
ES . I N
N O T
KTU
European Aluminum Assocation

http://www.eaa.net/downloads/auto.pdf
Aluminum Production
• Aluminum requires large amounts of
energy to extract ~ 6 – 8 times more
than steel
ES . I N
N O T
KTU
• However, recyclable without much loss

Aluminum Cans
• In 1998 879,000 metric tons of
Aluminum cans were recycled (63% of
all Al cans)
• Cans comprise lessOthanES . I N
30% of Al
U N T
products K T
• In 1998, 3.4 million metric tons of
Aluminum were processed from recycled
Aluminum (37%).
http://www.aluminum.org/Template.cfm?Section=Recycling
Summary of Autos
• Recycling steel and aluminum
• Replacing steel with aluminum
ES . I N
• Buying longer U O T
lasting
N automobiles
K T
with better fuel economy
• Using alternate means of
transportation

The Economics of Ecology
(or…covering your bottom
line) ES . I N
U N O T
K T
Pictures courtesy of http://pubs.wri.org/pubs_description.cfm?

PubID=3786 and http://www.kbnp.com/bl.htm
respectively.
Monterey Regional Waste Management
District Regional Environmental Park
• “Reduce, Reuse and Recycle”
• Hazardous Waste Mitigation
• Reselling materials instead of dumping
• S
Landfill Gas Power Project . I N
U N OTE
KT

Cape Charles
Sustainable Technology Park
ES . I N
U N O T
K T
Create 400 Jobs in first stage of development for Local Area
* 27% below poverty line
Redevelop Brownfields
Government Subsidy
Natural Habitat and Infrastructure
Solar Building Systems, Inc.
Energy Recovery
Market Failure
Negative Externalities
• Harm proportionate with output produced
• Harm increases at an increasing rate with output
produced (synergistic effect)
• Harm significant initially, increases at decreasing
rate with output produced ES . I N
N O T
KTU

Market Failure Correction:
Subsidies
ES . I N
N O T
KTU

Economic Benefits of IE
• Hidden Resource Productivity Gains
– Within Firm: eliminating waste
• Making plant more efficient
– Within Value Chain: S . I N
reducing costs
UTE
N O
• Synergies T
Kbetween production and
distribution
– Beyond Production Chain: closed
loop
• Eco-Industrial Parks and inter-firm relations

Benefits of IE to Corporation
• Revenue Generation
• Cost Savings
• Reduced Liabilities
• Competitive Edge of ES . I N
Regulatory U N O T
K T
Flexibility
• Enhanced Public
Image
• Market Leader

Barriers to Development
• Suitability of materials to reuse
• High cost of recycling (internalize
negative externalities)
• Information Barriers ES .
(mustI N set up
U N O T
reciprocal K T
relationships between
sectors)
• Organizational Obstacles
• Institutional Barriers (need fiscal and
regulatory government intervention)
Macro to Micro Scale of IE
• Macro: Industrial
Processes as a whole
• Meso: Sector
Interrelationships
• Micro: Individual ES . I N
N O T
KTU
Consumer/Producer
Behavior
• “Conspicuous
Consumption” and
Conspicuous Waste
Photo courtesy of: http://www.cpm.ehime-

u.ac.jp/AkamacHomePage/Akamac_E-text_Links/Veblen
IE: Other Examples
ES . I N
N O T
KTU

The Future of IE
ES . I N
N O T
KTU

Iceland’s
Hydrogen
Fueling
Station
ES . I N
N O T
KTU

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Green Engineering

Dr. P.R. Sreemahadevan Pillai

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

 Apply across disciplinesOTE S . I N

 Apply across scales of design

To get more study materails visit www.ktunotes.in

 Identify examples of successful engineering

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

 Life cycle foundation across all

To get more study materails visit www.ktunotes.in

investments (i.e., time, money, resources,energy)

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

"A Recyclable Catalyst that Precipitates at the End of the Reaction."

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

"If a system in equilibrium is subjected to a

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

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 Case for modular, standardized, platform-

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

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"When we reuse our products —

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

Dr. P.R. Sreemahadevan Pillai

To get more study materails visit www.ktunotes.in

Robert A. Frosch Nicholas E. Gallopoulus

To get more study materails visit www.ktunotes.in

• Essentially mimics natural systems

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

• Material, water, and energy flows

To get more study materails visit www.ktunotes.in

To get more study materails visit www.ktunotes.in

• Using renewable resources

• Long-lasting design of systems