green by design pratt & whitney’s green engine program columbia university industrial ecology...
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GREEN BY DESIGNPratt & Whitney’s Green Engine Program
Columbia University
Industrial Ecology Course
February, 2001
Pratt & Whitney
Bob TierneyPratt & Whitney - United Technologies Corporation
Today’s topics...
• United Technologies Corporation
• Pratt & Whitney’s Green Engine Program
• Our conception of Life Cycle Assessment
• Elimination of hazardous materials from life cycle
• Strategic thoughts on implementing green
Progress !!
Lead air emissions 98% decrease 1970-95
Lead in child’s blood 82% decrease 1976-95
CO emissions 30% decrease 1970-92
Auto hydrocarbons 98% decrease 1970-95
Lakes/ rivers 60% fully meet water stds.
Bald eagle off endangered species list
Sewage 100% treated in US (EU -72%)
U.S. data unless noted
Progress ??
Electricity use per capita 21 % increase 1977-87
Aluminum consumption 1200% increase 1970-88
CO2 concentration 7% increase 1975-95
Waste to landfills 34% increase 1970-90
Ozone hole 60% deeper 1970-95
U.S. data unless noted
The Master Equation
GlobalEnvi.
Impact= Population Resource
use Person
Unit of WasteUnit of ResourceX X
Drivers for Green
• State of the environment
• Customers
• Bottom line (Green = $$$$)
• Top Line Growth
• Wall St.
• Politics/ Regulations
• UTC Policy/ 10X Goals
* Based on 594 airports in Boeing database
050
100150200
250300
350400
1970 1980 1990 2000
Year
Noise AbatementProcedures
Curfews
Charges
Levels
Quotas
Budgets
Ch. 2 Phase-out
Ch. 2 Restrictions
Ch. 3 Restrictions
Nu
mb
er o
f R
estr
icti
on
s
Local Restrictions Increasing at an Accelerating Rate *
2/22/00http://www.boeing.com/assocproducts/noise/list.html
25
Green Engine Program is structured as a matrix organization
Management
Green Factory Technology
Design
Customer Requirements/
Communications
Suppliers
Life Cycle Assessment: The StagesFor the sake of simplicity the life cycle is divided into unit processes usually broken down as follows: pre-manufacture, manufacture, distribution and installation, use and service, and end of life management. Each unit process is then evaluated in three areas: safety, conservation, and pollution. The inputs and outputs of each life stage are the criteria for evaluation.
Pre-Manufacture
Manu-facturing
Revert
Reuse
Use &Service
RecoveryManagement
Distribution
Remanufacture
CO2 Emissions
0
20
40
60
80
100
120
MIL
LIO
N M
ETR
IC
TO
NS
OF C
O2
UTC
P&W FLEET
Factory vs. Use
55X
Develop Process Map with the “Goes-Ins” and the “Goes-Outs”
Inputs Outputs
Process or Activity
Product or Service
Raw MaterialsChemicalsEnergyFuelsElectricity
Actions of People, Equipment, MachinesReactions of Chemicals and Materials Injuries
IllnessesInefficienciesAir EmissionsWater DischargesSolid/Liquid Waste
By-products
Tap Into Existing Data Sources
Plating 5%
Stripping 9%
Painting 14%
Machining & Metalworking
8%
Degreasing 4%
Misc.. Sources
32%
Cleaning & Rinsing
11%
Surface Preparation & Treatment
17%
Hazardous waste sent off site by process source
Hazardous waste sent off site by process source
Ergonomic Injuries
57%
All Other Injuries43%
Maintenance & Service
11%
Manufacturing & Assembly
26%
Material Handling37%
Injuries by type and operation
Injuries by type and operation
Is it Good, Bad or Ugly?
EH&S IMPACTSLIFE STAGE MAKE PRODUCTS
& WORKPLACESAFE
PROTECTENVIRONMENT
CONSERVERESOURCES
PREMANUFACTURE
MANUFACTURE
DISTRIBUTION &INSTALLATIONUSE &MAINTENANCEEND OF LIFE
Has lowest possibleNoise Impact
Has the lowest possible Emission Impact during use
Contains Green Materials
Is designed with Human Factors
in mind
Has least possible Factory Impacts
Is Material Efficient (Metal Buy-to-fly,Propellant Yield )
Is manufactured andserviced usingGreen Processes
Involves Green Suppliers and Partners
Is Designed for Serviceability, Reusability, Recyclability
Is Energy Efficient during use (Fuel Burn)
Elements of a Green EngineVision: Pratt & Whitney sets the Standard for Green
LCA
Distribute
DesignSpecifications
SupplierManufacturing
ProcurementProcess
OperatingProcedures
P&WManufacturing
Goals
Job Ticket/SRD/ CRD
DesignStandard Work
UseServiceEnd of Life
Environment, Safety, Natural Resources Impact
Understanding Impacts is Key to Continuous Improvement
LCA
Distribute
DesignSpecifications
SupplierManufacturing
ProcurementProcess
OperatingProcedures
P&WManufacturing
Goals
Job Ticket/SRD/ CRD
DesignStandard Work
UseServiceEnd of Life
Environment, Safety, Natural Resources Impact
Green FactoryTeam
TechnologyTeam
DesignTeam
Customer Req’mt Team
SupplierTeam
Knowing Where to Apply the ‘Green’ Pressure Points
LCA as Part of Integrated Program Deployment (IPD)
Aspects & Impacts
Objectives & Targets
EH&S ANNUAL PLANNING& EVALUATIONEH&S ANNUAL PLANNING& EVALUATION
PRODUCT LIFE CYCLE ASSESSMENT
PLANNING DEFINITION VALIDATION DELIVERY SUPPORT
Product Requirements
Market Feedback Analysis
TECHNICAL SUPPORT
Baseline LCAs are the Standard by Which Future Products Are Compared
Large Gas Turbine Engine
General Aviation Engine
Liquid Rocket (expendable & serviceable)
Solid Rocket (expendable & serviceable)
What is a Life Cycle Assessment?•Qualitative process used to assess EH&S impacts of product during its lifecycle
What does it provide?•Relative magnitude of EH&S impacts•Areas of information gaps•Priorities for green design•Priorities for green technology development
And….•Raises consciousness of organization
Materials/ Processes of Concern
MATERIALS OF CONCERN FOR GAS TURBINE AND ROCKET PROPULSION SYSTEMS
• Materials Of Concern
• Hazardous Materials Index
• Product Comparisons
• Standard Work
• Green Technology Goals
• Summary
Materials Of ConcernObjectives
• Identify hazardous material risks across the enterprise
• Provide a deliverable for incorporation into standard work
• Create a green index to drive green technology plan
Rationale
• Appearance of targeted materials on one or more industry, customer or regulatory list(s) of hazardous materials
• Relevance to Pratt & Whitney product lines or processes
• Potential linkage to product and process design callouts
Definition Of Categories• Prohibited
– high risk materials not permitted in new design and development
• Restricted– high risk materials that can only be used with appropriate
levels of approval
– plan must be established to validate alternate green material
• To Be Reduced– materials known to have detrimental environmental, health
and safety impacts.
Materials of Concern
Arsenic & compoundsAsbestosBenzeneBerylliumCadmium & compoundsChlorinated solventsEthyl alcoholEthylene glycol ether compoundsFormaldehydeMercury & compoundsMethanol (methyl alcohol)Methylene chlorideClass I ozone depleting substancesRadioactive materials, including Thoriated (TD) nickelToluene diisocyanate
Chromium, hexavalentClass II ODSCyanides DimethylformamideHCFC-14 lb & HCFC-22HydrazineHydrofluoric acidHydrogen fluoride gasLead & compoundsManmade fibers, e.g., cristobalite, fiberfraxMDA (4’, 4’-Methylenedianiline)Methyl alcohol (methanol)Methyl ethyl ketone (MEK, 2-butanone)Methyl iso-butyl ketone (MIBK, 4-methyl-2-pentanone)PhenolStyreneTolueneXylene
AcetoneAmmoniaButyl alcoholEthyl benzenen-HexaneHydrochloric acidIsocyanatesn-methyl-2-pyrrolidoneIsopropyl alcoholNickel plateNitric acidPetroleum distillates (e.g., naptha, mineral spirits, stoddard solvent, varsol, evaporative lubricants)Phosphoric acidSec-butyl alcoholSulfuric acid1, 2, 4-Trimethylbenzene
Prohibited Restricted To Be Reduced
Hazardous Materials Index• Purpose
– provide metric to define “greenness” of products
– link materials to specifications/design callouts
• Assign “toxicity” values to materials & process specifications based on Purdue University rankings
• Quantify green indices based on Pratt & Whitney Canada algorithm:
Ih = T*nP/N
where: Ih = Hazardous Material Index
T = toxicity value of specification
nP = number of part numbers that call out specification
N = total number of part numbers in engine
Hazardous Materials Index
Implementation
• Establish metrics/set goals
• Establish signoff/approval protocols
• Control via standard work
Restricted Materials of Concern - Current Status of Various Engine Programs
0
5
10
15
20
25
30
JT8D-219 PW2037 PW4168 Goal
Ha
zard
ou
s M
ate
ria
ls In
de
x
Technology Opportunity
Standard WorkMaterials Of Concern
• Contains background, contacts and protocols
• References material and process specification list
• Links to data base containing materials of concern,
toxicity rating detail, identified by specifications
• Links to menu for selection of alternate materials and
processes, cross-referenced by specification
Materials of Concern List with Specification Number
Specification Number Hazardous Material
PWA-316 Lead
PWA-333 Xylene, Toluene
AMS-3110 Chromium, Toluene
QQ-P-416 Cadmium
PWA-315 None
PWA-1469-3 None
AMS-3242 None
Green Technology Goals
• Goals established based on driving down product hazardous materials index
• Goal for legacy products will be based on designing out prohibited materials
• Goal for new designs will be based on eliminating the use of restricted materials
Summary
• Comprehensive effort to identify hazardous
material risks across the Pratt & Whitney
enterprise
• Risks defined by levels of concern
• Standard work tool for designers established
• Goals in process of being defined
• Hazardous Materials Index will drive technology
Rod Elkington, Chairman:
“Tomorrow’s economy will be about increasing returns where we learn to exploit virtuous cycles rather than manage vicious ones.”