intro to life cycle energy assessment of a...
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Intro to Life Cycle Energy
Assessment of a Product
1
Mat’l
Prod
Mfg. Use EOL
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Manufacturing of a Product
2
Mat’l
Prod
Mfg. Use EOL
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Major Energy & Mat’l Flows
Mining
&
Mat’ls
MfgProcess
Energy InputsEnergy Inputs
Material
Inputs
Product
Waste Materials Waste Materials
Material
Inputs
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Em
bodie
d E
nerg
y in M
ate
rials
fro
m K
alp
akjia
n
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Gold ~ 250 GJ/kg
Ashby 20095Oct 15, 2018 2.810
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Gold ~ 250 GJ/kg
Ashby 20096
Mat’l GJ/kg
Ag 2
Pd 35-50
Au ~70
Pt ~117
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7
See extra slides at end
Nominal Mfg Process Rates
Vary by more than 8 orders
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See extra slides at end
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Junk and Cote 2012
9.4E-03 kg/hr,1.8 to 2.3 E+08 J/kg
Corman 2014
1.2 to 1.8 E-02 kg/hr, 4.1E+07 J/kg to 2.9 E+08
J/kg
EPRI 2014
2.2E-02 kg/hr, 2.8 to 4.0 E+08J/kg
EPRI 2014 , BAAM,
10.0 kg/hr, 4.0E+06 J/kg
Telenko et al. 2011,
2.6E-02 kg/hr, 5.0E+08 J/kgBaumers et al. 2011,
4.1E-01 kg/hr, 2.0E+08 J/kgKellens et al. 2011,
4.1E-02 kg/hr, 1.3E+08 J/kg
Morrow et al. 2005,
3.6E-03kg/hr, 7.7E+09 J/kg
Baumers et al. 2010 ,
1.3E-01 kg/hr, 6.1E+07 J/kg
EPRI 2014,
8.9E-02 kg/hr, 1.1E+08 J/kg
Faludi et al. 2017 Full bed,
1.1E-02 kg/hr, 5.7E+08 J/kg
Faludi et al 2017 Single bed,
4.0E-02 kg/hr,1.2E+09 J/kg
Baumers et al. 2010 Full bed,
5.6E-02 kg/hr,1.1E+08 J/kg
Baumers et al. 2010 Single bed,
4.0E-02 kg/hr, 1.4E+08 J/kg
EPRI 2014
Binder jetting, 6.5E-03 kg/hr, 8.3E+07 J/kg
1.E+05
1.E+06
1.E+07
1.E+08
1.E+09
1.E+10
1.E+11
1.E+12
1.E+13
1.E+14
1.E+15
1.E-06 1.E-05 1.E-04 1.E-03 1.E-02 1.E-01 1.E+00 1.E+01 1.E+02 1.E+03 1.E+04 1.E+05 1.E+06
Ele
ctr
icit
y R
equ
irem
ents
[J/
kg]
Process Rate [kg/hr]
cupola Electric Induction Melting Injection Molding
Machining Finish Machining CVD
Sputtering Grinding Waterjet
Wire EDM Drill EDM Oxidation (Semiconductor)
Material Extrusion: FDM Material Extrusion: BAAM Powder bed fusion: Polymer, laser
Directed energy deposition: DMD Powder bed fusion: Metal, eletron beam Powder bed fusion: Metal, laser
Binder jetting
50 kW 5 kW
500 W
Measured 3D Printing
energy intensity (J/kg)
Vs Print rate (kg/hr) for AM
(metals in red,
plastics in blue)
overlaid on conventional
manufacturing processes.
(Gutowski et al 2017 JIE)
BAAM technology
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Scrap rates from Kalpakjian
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Two Examples
Machining of an aluminum bracket:
(part mass = 444g,
starting block = 9cmX12cmX30cm
= 3240cm3 x2.7g/cm3 = 8748g
waste = 8304g)
Injection molding of a PET container
(hot runner, little waste, part = 67g,
High volume so ignore tooling)
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Machining of an aluminum
bracket (*ref Ashby)Primary Aluminum: ~200MJ/kg*
~ 12kg CO2/kg*
Secondary Aluminum: ~25MJ/kg*
~ 2kg CO2/kg*
Scrap = Waste/Starting Block = 8304/8748 = 95%
Buy/Fly = Starting Block/Part = 8748/444 = 20
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Machining of an aluminum
bracket
• 200MJ/kg X block (8.75 kg) = 1750 MJ
• 3MJelect/kg X 3grid = 9MJ/kg X scrap (8.3
kg) = 75 MJ
• Embodied energy in the material
dominates 1750MJ + 75MJ = 1825 MJ• Ref: gal of gasoline 115MJ,
World annual average: 65GJ/capOct 15, 2018 2.810 13
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Injection molding of a PET
container (ref Ashby*)
Primary PET: ~85MJ/kg*
~ 4kg CO2/kg*
Secondary PET:~40MJ/kg*
~ 2.3 kgCO2/kg*
Injection Molding from pellets, hot runner =
(3MJextrusion/kg + 3MJ injection molding/kg) X 3 = 18MJ/kg
Little scrap, again materials dominate 5.7 + 1.2 = 6.9MJ
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These are rough estimates,
better estimates require more
details…but you get the idea.
• What if the aluminum scrap was
recycled?
• What if the aluminum part was cast, or
AM?
• What if the plastic part was made by
FDM?
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Extra slides
• Boundaries for analysis
• Sample values for the production of
polymers
• Compounding
• Hydraulic Vs electric machines
• Driers
• Recycling
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Polymer ProductionLargest Player in the Injection Molding LCI
What is a polymer:
How much energy does it take to make 1 kg of polymer = a lot !!!
Values are in MJ per kg of polymer produced. Thiriez ‘0618Oct 15, 2018 2.810
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Compounding - extrusion
• An extruder is used to mix additives with a polymer base, to
bestow the polymer with the required characteristics.
• Similar to an injection molding machine, but without a mold
and continuous production.
• Thus it has a similar energy consumption profile.
Environmentally Unfriendly Additives:
•Fluorinated blowing agents (GHG’s)
•Phalates (some toxic to human
liver, kidney and testicles)
•Organotin stabilizers (toxic and
damage marine wildlife)
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Injection Molding Process
Source:
http://cache.husky.ca/pdf/br
ochures/br-hylectric03a.pdf
Machine types: Hydraulic, electric, hydro-electric
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All-electric vs. hybrid
The hydraulic plot would be even higher than the hybrid curve
Source: [Thiriez]
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For Hydraulics and Hybrids as throughput
increases, SEC → k.
Enthalpy value to melt plastics is just 0.1 to 0.7 MJ/kg !!!
Does not account for the electric grid. Source: [Thiriez]
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All-electrics have very low fixed energy costs (small
idling power). SEC is constant as throughput
increases.
Source: [Thiriez]23Oct 15, 2018 2.810
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Driers• Used to dry internal moisture in hygroscopic polymers and external
moisture in non-hygroscopic ones.
• It is done before extruding and injection molding.
Source: [Thiriez]
Same as24Oct 15, 2018 2.810
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Do Polymers get recycled?
Ref Ashby 200925Oct 15, 2018 2.810
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The printer goes in the hopper…
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And comes out….
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