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Toxics Use Reduction Institute
Design for Environment (DfE)Making products green - really
Toxics Use Reduction Institute
Mark Myles
Clark UniversityMaterials & Energy Sustainability
26 February 2011
MA Toxics Use Reduction
• 50% reduction in generation of toxic waste by 1997 through TUR
• Establish TUR as the preferred means of regulatory compliance
• Sustain and promote the competitive position of Massachusetts industry
• Promote reduction in the production of toxic and hazardous substances
• Enhance and coordinate state agency enforcement of environmental laws
Great Philosophical Dilemmas of the 21st Century
Plastic?(polystyrene)
OR
Paper?
Hocking paper in Science (Feb. 1991):Paper vs Polystyrene, a Complex Choice
• Wood product use: 33g• Petroleum material: 4.1g• Steam: 9-12 tonne/T• Electricity: 980 KWh/T• Cooling water: 50 m3/T• Water effluent: 50-190 m3/T• H2O solids: 35-60 kg/T• Metal salts to H2O: 1-20 kg/T• Low recycled use (coating
removal)• Biodegradable with BOD* lechate
and CH4 to air• Clean incineration
• Wood product use: 0• Petroleum material: 3.2g• Steam: 5 tonne/T• Electricity: 120-180 KWh/T• Cooling water: 154 m3/T• Water effluent: 0.5-2 m3/T• H2O solids: trace• Metal salts to H2O: 20 kg/T• High recycled use (resin re-use)• Inert, non-biodegradable• Clean incineration
Paper CupPaper Cup Polystyrene CupPolystyrene Cup
* Biological Oxygen Demand
DfE is more than ‘design’
• DfE success ties to Quality processes
• DfE is a strategic decision
• DfE is cross-functional• DfE is systemic, holistic,
and synergistic• DfE may be counter-
intuitive
What makes a product ‘green’?
Lowell Center for Sustainable Production -
Framework for Sustainable Products
DfE Definitions
• “…product contains only those ingredients that pose the least concern [regarding human health and environmental effects] among chemicals in their class.”
• “Ecodesign aims at reducing the environmental impact of products, including the energy consumption throughout their entire life cycle.”
DfE Definitions
“The DfE program has three priorities:
• Energy efficiency - reduce the energy needed to manufacture and use our products
• Materials innovation - reduce the amount of materials used in our products and develop materials that have less environmental impact and more value at end-of-life
• Design for recyclability - design equipment that is easier to upgrade and/or recycle”
From Take-Make-Waste….
…to Cradle-to-Cradle
Drivers: Legislation
REAChRoHSTURAToSCA
EU Energy CA Appliance Efficiency
MA “Stretch Codes”
Energy
Toxics ResourceConservation
WEEEELV
EU Ecodesign Directive: all 3
Drivers: Labeling and Certification
Drivers: Consumer Preference
Making DfE Happen
Total Quality Management
Focus on identifying defects in every step
Continuous improvement
= The Better Mousetrap:• Higher quality • More reliable• Better focused on customer
need• Cheaper
Total Quality Environmental Management
Consider non-compliance and adverse environmental impact to be defects
Existing TQM practices
= The Greener Mousetrap:• Environmentally compliant• Designed for the
Environment• ISO Life cycle oriented
Quality Costs
Supplier Inspection
Incoming Inspection
Fabrication Inspection
Sub-product Test
Final Product Test
Field Service
0.003
0.03
0.30
$3
$30
$300
Quality costs escalate as value is added to a product or service
Cost of finding and correcting a defective electronic component
P. Crosby & Associates, 1979
Environmental Quality Costs
Product concept
Landfill, incineration, etc.
Environmental cleanup
Manufacture
Design
Use
Life Cycle Costs escalate at later stages of the Life Cycle
Life Cycle Cost of a toxic material
“Most environmental costs are incurred on the first day of product development”
Environmental Quality Costs
Product concept
Landfill, incineration, etc.
Environmental cleanup – landfill toxics remediation
Manufacture
Design
Use
Life Cycle Cost of Mercury battery
One ‘button battery’ per kg of soil renders cost
of soil remediation virtually infinite
Theoretical Environmental Quality Costs
Product concept
Landfill, incineration, etc.
Environmental cleanup – landfill remediation
Manufacture
Design
Use
Life Cycle Cost of rechargeable alkaline and Lithium-ion batteries
Relatively expensive to purchase, these
batteries last much longer, are less toxic,
are rechargeable,and can be recycled
easier.
Theoretical Environmental Quality Costs
Product concept
Landfill, incineration, etc.
Environmental cleanup – landfill remediation
Manufacture
Design
UseSelf-powered windup devices minimize the
problem of battery disposal
Life Cycle Cost of windup flashlight
Examples of DfE factors
Low power logic family vs standard logic families
Design Choice
Recycled pulp inserts vs styrofoamPackaging
Gold circuit board traces vs copperMaterial Recovery
Improved Design for DisassemblyRecyclability
‘Always on’ power adaptor vs ‘Smart’ power adaptor
Energy Consumption
Plastic housing vs metalMaterial Choice
Inkjet vs laserProduct Concept
Life-Cycle Analysis (LCA)
• Consider products or product options which deliver equivalent function
• Model chains of engineering unit processes, their resource/pollution flows
• Sum resource/pollution flows over chain (inventory analysis – LCIA)
• Determine damage potentials – impact analysis
• Optimize environmental performance throughout the product’s entire life
Life Cycle Analysis (LCA)
Fossil Fuel DepletionFossil Fuel Depletion
Mineral DepletionMineral Depletion
Land UseLand Use
Water acidification / eutrophicationWater acidification / eutrophication
Eco-toxicityEco-toxicity
Climate ChangeClimate Change
Ozone Layer DepletionOzone Layer Depletion
Carcinogenic SubstancesCarcinogenic Substances
Organic Respiratory EffectsOrganic Respiratory Effects
Inorganic Respiratory EffectsInorganic Respiratory Effects
Ionizing RadiationIonizing Radiation
Ecosystem Resources
Ecosystem Resources
Ecosystem Quality
Ecosystem Quality
Human Health
Human Health
Impact Categories (“Midpoints”) Typical Groupings Endpoints
Modeling chains of unit function – unit process
Extractions from the environment• Fuel• Materials • Land, water, air, etc.
Could be from biosphere or technosphere
Emissions to the environment• To air• To water
Product or service
From previous unit
process(es)
To next unit process(es)
Releases to environment
Extractions from environment
System boundary
Modeling chains of unit function – chains of units
Laser printer example – Life Cycle Inventory hierarchy
Life cycle:laser printer
Product assembly Electricity use
Subassembly – housing
Scenario – office waste
Waste scenario - incineration
Electricity use Electricity use
Sheet metal milling / rolling
Sheet metal production
Paper use Toner use
Waste scenario - landfilling
Subassembly – power supply
Subassembly – electronic parts
Oxygen production
Coke production
Scrap collection
Actual Software Example Life Cycle Inventory hierarchy
Summing resource and emission flows, calculating impact results
Inventory results (LCI) Impact Assessment results
Impact group results – comparing alternatives
Impact group results – comparing weighted alternatives
Issues with LCA
• Relative importance of various midpoints & endpoints– E.g., which is more serious – Global Warming
potential or carcinogenic emissions to water?
• Difficulty of getting data– E.g., what’s the silver yield of Bolivian ore?
• Inappropriate data and assumptions– E.g., sulfur content of Chinese vs US coal
• Lies, damned lies, and statistics
Eco-efficiency
• Jointly considers financial and environmental costs
• Guides development investment decisions
0
0.5
100.51
Cost burden
LCA
sco
re
Incr
easin
g ec
o-ef
ficien
cy
Product option A
Product option B
Product option C
Thank you!
Mark MylesToxics Use Reduction Institute
600 Suffolk St., 5th FloorWannalancit MillsLowell, MA 01854
[email protected]+1 978.934.3298