Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:1 Environmentally Conscious Design & Manufacturing Class 6: Reuse / Recycle Prof. S. M. Pandit

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:2 Reuse / Recycle Agenda l Motivation l Design issues & inverse manufacturing l Discrete product recycling l Tools l Expert systems

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:3 Motivation 1991Carnegie Mellon Report Projection: 150,000,000 obsolete PCs by 2005 None with readily recoverable materials Landfilled! Cost: $ 400,000,000 What about washing machines, refrigerators, etc.?

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:4 Design Issues - 1 Inverse Manufacturing Not limited to reusing and recycling -- Develop methods for the creation of designs with thought given to reuses and recycling from the very early stage -- Improve the functions of a product along with prolonging its product life through use and maintenance -- Lower the amount of abandoned artifacts.

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:5 Design Issues - 2 Green Design -- How to arrange the information for design and development leading to the formation of an artifact system symbiotic with the environment. --New artifacts born out of this sort of methodology will have considerable effect in creating the new industries of the future.

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:6 Design Issues - 3 l Extension of Reuse / recycle concepts: Maintenance Issues -- The manufacturing industry will turn into a life cycle industry --The artifacts produced will quantitatively decrease --But they will, instead, have »A long life and »Give rise to higher added values and the manufacturing industry will become sustainable.

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:7 Design Issues - 4 l Reuse / Recycling in sustainable manufacturing --Develop methods serving toward the creation of designs with thought given to reuse and recycling from the very early stage --Improve the functions of artifacts, while decreasing the production volume but maintaining the level of economic activities.

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:8 Recycling - Options & Hierarchy Maintenance Recycle subassemblies Recycle components Recycle materials

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:9 Hierarchy of Preference in Recycling - 1

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:10 Hierarchy of Preference in Recycling - 2

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:11 Hierarchy of Preference in Recycling - 3

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:12 Closed-loop Recycling

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:13 Open-loop Recycling

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:14 Recycling Materials - 1 Avoid -- Too many different materials --Toxic materials --Joining dissimilar materials hard to separate Metals -- Dilution factors affect price (of Extraction)

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:15 Relation between Dilution and Price

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:16 Recycling Materials - 2 Plastics --Composition affects chemistry for recycling Tag with symbol Fastening methods

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:17 Recycling Materials - 3 Priorities for recycling: -- Reduce materials content -- Reuse / refurbish -- Remanufacture -- Recycle -- Incinerate -- Dispose of as waste Preference

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:18 Tools - 1 Hierarchy for recycling / Reprocessing -- pairwise comparison techniques Look at available technology Feasibility of developing technology Cost and time factors

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:19 Tools - 2 Choosing between alternatives: -- Reprocessability index for products & subassemblies -- Pairwise comparison

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:20 Tools - 3 Disassembly options (operations planning) Engineered materials Adsorb/ absorb contaminants Bio- degradation Experimental & analytic tools -- Effluent gases, caloric values, incineration options

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:21 Tools - 4

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:22 Recycling Program Steps Evaluation Design & Development Education Implementation Monitoring & Management Transportation, Processing & Marketing

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:23 Expert Systems Inference Engine Tree structure “If-Then-Else” Rules Analytic models Hybrids Empirical models Learning algorithms Imprecision “fuzzy” Inputs External Data Output ProcessorStructured Data Base

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:24 Homework #2 The following problems are out of the textbook “Industrial Ecology” 1. Problem 2.3 Answer: (Example of aluminum) yearPop(billion)Al(million tons)Al per capita (g/person) Problem 2.4 Answer: 2000: 23; 2010: 14 g; 2020: 6.2 g SO 2 /dollar Hint: Use extrapolation beyond the curves of Fig. 2.8)

Environmentally Conscious Design & Manufacturing (ME592) Date: March 17, 2000 Slide:25 Homework #2 3. Problem 3.2 Answer: 1.5%(current fraction), 1.0%( 2020 fraction). 4. Problem 4.1 Answer:Draw a vertical line from 1.1 mg/l, and picture moving all of the curves to the right by half a division (i.e., factor of three in the log). The intersection is with the log probit curve. The Weibull model would have given approximately 2*10 4 µg/l as the standard, the logit model approximately 0.3 µg/l, and the multistage model approximately 30 µg/l.