1. Decision Analysis Framework for the Industrial Sustainability Analysis of the Surface Finishing Industry Cristina Piluso and Yinlun Huang Department of Chemical Engineering & Materials Science Wayne State University Detroit, MI 48202, USA International Conference on Sustainability Engineering and Science Auckland, New Zealand February 20-23, 2007

2. Need for Analysis Methodology Ecological Input-Output Flow Analysis (EIOA) Quantification of Environmental and Economic Sustainability Using Sustainability Metrics Introduction of a Decision-Analysis Framework Case Study on Zinc Plating Network Flow Concluding Remarks Outline

3. Strong interdependence among industrial entities –Efforts to satisfy triple bottom line strongly dependent on efforts of other entities –Major opportunities exist for synergistic improvements among plants Need for general and systematic analysis methodology –Sustainable development of entity, industry, and region Need for Analysis Methodology

4. Mathematical core of industrial sustainability analysis Full characterization of all direct and indirect flows that support a specific waste or product outflow Captures big picture and detailed inter- relationships among entities in region Ecological Input-Output Flow Analysis (EIOA)

5. Node – Process unit, industrial entity, etc. Flow – Information input/output of a node (material, energy, etc.) H i = Processing node i f ij = Flow from H j to H i y w,0i, y p,0i = Outflow from H i z i0 = Inflow to H i

6. Ecological Input-Output Flow Analysis (EIOA) Throughflow: Sum of all outflows from a node

7. EIOA Inflow Analysis Determination of the origin of each outflow from system Instantaneous Fractional Inflow Matrix, Q* –Calculated by dividing each element of P by throughflow of i-th row of P –An element of Q* is fraction of total flow through a node attributable to inflow, outflow, or internodal flow

8. EIOA Inflow Analysis Transitive Closure Matrix, N * –Element of = relationship inflows have with flows to H i –Element of = total flow through H j needed to produce a unit of flow to H i –Element of = amount of inflow needed to produce a unit of each outflow from H i –Element of = total flow through H j needed to produce a unit of each outflow from H i Define N * as:

9. EIOA Environ Analysis Traditional Environ,, (flow units/unit waste); the set of flows necessary to produce a unit of outflow Actual Environ,, (flow units); the actual flow magnitudes necessary to produce each outflow Percentage Environ,, (%); the percent of a given flow used to produce each outflow

10. EIOA provides information to: –Trace industrial waste and product streams back to their origins –Determine which flows the output is most dependent on How to quantify sustainability? Quantification of Sustainability Using Metrics

11. Environmental Sustainability Metric [1] –Mass Intensity = Total Mass In / Mass of Product Sold –The smaller the better Economic Sustainability Metric [2] –Gross Profit = Net Sales – COGS –The larger the better [1] AIChE Center for Waste Reduction Technologies (CWRT). Collaborative Projects – Focus Area: Sustainable Development, AIChE: New York, 2000 [2] IChemE. The Sustainability Metrics – Sustainable Development Progress Metrics Recommended for use in the Process Industries, IChemE: Rugby, UK, 2002 Quantification of Sustainability Using Metrics

12. Second layer of analysis needed to provide meaningful sustainability decision-analysis abilities The decision-analysis framework: –Evaluates current state of industrial sustainability –Aids in making systematic and strategic decisions Introduction of a Decision-Analysis Framework

14. Decision-Analysis Framework – Environmental Sustainability Analysis

15. Decision-Analysis Framework – Economic Sustainability Analysis

16. Case Study on Zinc Plating Network Flow

17. Zinc Plating Network Flow Case Study Mass IntensityGross ProfitSystem Type Overall System 1.307$306,429 Chemical Supplier #1 1.075$14,062 Chemical Supplier #2 1.136$3,514 Plating Shop #1 1.167 $160,508 1.183$18,315 Automotive OEM #1 1.053$109,783 Automotive OEM #2 1.031$-1,922 Plating Shop #2 EnvironmentalEconomic

18. Zinc Plating Network Flow Case Study - Results Plating shop #1 waste generation is most dependent on: –Internal reuse (11.4%) –Raw material from both suppliers (11.4%) –Recycle from OEM #1 (11.4%) –Raw zinc to supplier #1 from environment (10.6%)

19. Zinc Plating Network Flow Case Study - Results Suggested Network Modifications: –To reduce amount of waste generated by plating shop #1 Increase the recycle from OEM #1 Increase internal reuse –Similar analysis can be performed for remaining waste streams

20. Zinc Plating Network Flow Case Study - Results Mass IntensityGross Profit System Type w/o mod.w/ mod. Overall System 1.307 Chemical Supplier #1 1.075 1.136 Plating Shop #1 1.167 1.183 Automotive OEM #1 1.053 1.031 w/o mod.w/ mod. EnvironmentalEconomic % change Chemical Supplier #2 Plating Shop #2 Automotive OEM #2 1.199 1.053 1.087 1.158 1.211 1.042 1.031 8.26 2.05 4.31 0.77 -2.37 1.04 0.00 $306,429 $14,062 $3,514 $160,508 $18,315 $109,783 $-1,922 $387,236 $15,642 $4,742 $226,975 $26,656 $108,421 $-3,656 20.20 10.10 25.90 29.28 31.29 -1.26 -47.43

21. Concluding Remarks Through Percentage Environs we can: –Trace industrial waste and product streams back to their origins –Determine which flows the output is most dependent on Combination of EIOA, sustainability metrics, and decision-analysis framework: –Identifies changes to be made to realize improved state of environmental and economic sustainability

22. National Science Foundation – DMI 0225844, and DGE 9987598 Wayne State University – Institute of Manufacturing Research Acknowledgments