Green Engineering Principles and Practice Jennifer L Anthony
![Green Engineering: Principles and Practice Jennifer L. Anthony Department of Chemical Engineering Kansas State Green Engineering: Principles and Practice Jennifer L. Anthony Department of Chemical Engineering Kansas State](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-1.jpg)
![“Green chemistry is a multidisciplinary field involving fundamental sciences, business, law, and engineering. ” “Green chemistry is a multidisciplinary field involving fundamental sciences, business, law, and engineering. ”](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-2.jpg)
![Engineering Role • Environmental remediation – Air – Water – Soil • Design / Engineering Role • Environmental remediation – Air – Water – Soil • Design /](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-3.jpg)
![Balance in Design Past Balance in Design Past](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-4.jpg)
![Balance in Design Present Balance in Design Present](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-5.jpg)
![Balance in Design Economical vs. Environmental Balance in Design Economical vs. Environmental](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-6.jpg)
![12 Principles of Green Engineering 1. 2. 3. 4. 5. 6. 7. 8. 9. 12 Principles of Green Engineering 1. 2. 3. 4. 5. 6. 7. 8. 9.](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-7.jpg)
![Principle 1 • Inherent rather than circumstantial “designers should evaluate the inherent nature of Principle 1 • Inherent rather than circumstantial “designers should evaluate the inherent nature of](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-8.jpg)
![A Case Study: Acrylamide vs. N-vinyl Formamide Highly toxic, causes CNS paralysis ~ $1/kg A Case Study: Acrylamide vs. N-vinyl Formamide Highly toxic, causes CNS paralysis ~ $1/kg](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-9.jpg)
![Acrylamide Synthesis Enzymatic route newest, greenest approach Process green, Product not Acrylamide Synthesis Enzymatic route newest, greenest approach Process green, Product not](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-10.jpg)
![NVF Production BASF Process HCN, an inherent hazard, raises costs Product green, Process not NVF Production BASF Process HCN, an inherent hazard, raises costs Product green, Process not](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-11.jpg)
![Principle 2 • Prevention rather than treatment “it is better to prevent waste than Principle 2 • Prevention rather than treatment “it is better to prevent waste than](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-12.jpg)
![2 example: how to prevent pollution? • Implementation of new technology –solvent substitution –eliminate 2 example: how to prevent pollution? • Implementation of new technology –solvent substitution –eliminate](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-13.jpg)
![2 example: how to prevent pollution? • Simple (no/low cost) solutions – sloping piping 2 example: how to prevent pollution? • Simple (no/low cost) solutions – sloping piping](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-14.jpg)
![2 example: how to prevent pollution? • Engineering changes – raw materials; pretreatment of 2 example: how to prevent pollution? • Engineering changes – raw materials; pretreatment of](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-15.jpg)
![LLE vs. Distillation: acetic acid/water separation Acetic Acid Tb = 118. 2 °C Dhvap LLE vs. Distillation: acetic acid/water separation Acetic Acid Tb = 118. 2 °C Dhvap](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-16.jpg)
![ethyl acetate + acetic acid aqueous acetic acid LLE distillation ethyl acetate acetic acid ethyl acetate + acetic acid aqueous acetic acid LLE distillation ethyl acetate acetic acid](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-17.jpg)
![Combined reaction/separation C 2 H 6 C 2 H 4 + H 2 C Combined reaction/separation C 2 H 6 C 2 H 4 + H 2 C](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-18.jpg)
![Combined reaction/separation H 2 C 2 H 6 C 2 H 4 H 2 Combined reaction/separation H 2 C 2 H 6 C 2 H 4 H 2](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-19.jpg)
![Principle 3 • Design for Separation; “many traditional methods for separation require large amounts Principle 3 • Design for Separation; “many traditional methods for separation require large amounts](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-20.jpg)
![Design for Separation, the Serendipitous Result…. . Polypropylene Cap (sometimes present…) Aluminum Ring Polyethylene Design for Separation, the Serendipitous Result…. . Polypropylene Cap (sometimes present…) Aluminum Ring Polyethylene](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-21.jpg)
![Recycling of PET bottles Color sort using spectroscopy; green dye chemically incorporated into PET Recycling of PET bottles Color sort using spectroscopy; green dye chemically incorporated into PET](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-22.jpg)
![Principle 4 • Maximize efficiency “products, processes, and systems should be designed to maximize Principle 4 • Maximize efficiency “products, processes, and systems should be designed to maximize](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-23.jpg)
![4 example: heat integration 170 k. J cooling utility (e. g. , cooling water) 4 example: heat integration 170 k. J cooling utility (e. g. , cooling water)](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-24.jpg)
![4 example: heat integration 30 k. J cooling utility (e. g. , cooling water) 4 example: heat integration 30 k. J cooling utility (e. g. , cooling water)](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-25.jpg)
![Principle 5 • Ouput-pulled rather than input-pushed “approaching design through Le Chatelier’s Principle, therefore, Principle 5 • Ouput-pulled rather than input-pushed “approaching design through Le Chatelier’s Principle, therefore,](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-26.jpg)
![Gap uses RFID tags to keep track of amounts on shelves versus amounts in Gap uses RFID tags to keep track of amounts on shelves versus amounts in](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-27.jpg)
![Principle 6 • Conserve complexity “embedded entropy and complexity must be viewed as an Principle 6 • Conserve complexity “embedded entropy and complexity must be viewed as an](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-28.jpg)
![6 example: PCs • IBM PC’s used to be made with 15 different types 6 example: PCs • IBM PC’s used to be made with 15 different types](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-29.jpg)
![Principle 7 • Durability rather than immortality; “It is therefore necessary to design products Principle 7 • Durability rather than immortality; “It is therefore necessary to design products](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-30.jpg)
![Example: CFC’s • • • Cx. Hy. Fz. Clq Non-flammable Non-toxic Inexpensive Effective Stable Example: CFC’s • • • Cx. Hy. Fz. Clq Non-flammable Non-toxic Inexpensive Effective Stable](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-31.jpg)
![Example: CFC’s • • • Cx. Hy. Fz. Clq Non-flammable Non-toxic Inexpensive Effective Stable Example: CFC’s • • • Cx. Hy. Fz. Clq Non-flammable Non-toxic Inexpensive Effective Stable](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-32.jpg)
![Principle 8 • Meet Need, Not Excess “design for unnecessary capacity or capability (e. Principle 8 • Meet Need, Not Excess “design for unnecessary capacity or capability (e.](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-33.jpg)
![8 example: whole industry overcapacity • Global auto industry has 80 million vehicles/yr capacity 8 example: whole industry overcapacity • Global auto industry has 80 million vehicles/yr capacity](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-34.jpg)
![Principle 9 • Minimize material diversity “options for final disposition are increased through upfront Principle 9 • Minimize material diversity “options for final disposition are increased through upfront](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-35.jpg)
![Examples • Automobile design: use single materials rather than alloys (metal and polymeric) • Examples • Automobile design: use single materials rather than alloys (metal and polymeric) •](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-36.jpg)
![Principle 10 • Integrate Material and Energy Flows “design of products, processes, and systems Principle 10 • Integrate Material and Energy Flows “design of products, processes, and systems](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-37.jpg)
![10 example: Ethanol for Gasoline • Ethanol from fermentation of biomass > ~15 wt% 10 example: Ethanol for Gasoline • Ethanol from fermentation of biomass > ~15 wt%](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-38.jpg)
![10 example: Ethanol for Gasoline Alternative • Direct contact of fermentation broth with gasoline 10 example: Ethanol for Gasoline Alternative • Direct contact of fermentation broth with gasoline](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-39.jpg)
![10 example: Kalundborg Industrial Park Novo Nordisk sulfuric acid plant sulfur refinery waste treatment 10 example: Kalundborg Industrial Park Novo Nordisk sulfuric acid plant sulfur refinery waste treatment](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-40.jpg)
![Principle 11 • Design for commercial afterlife “To reduce waste, components that remain functional Principle 11 • Design for commercial afterlife “To reduce waste, components that remain functional](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-41.jpg)
![Examples • Conversion of old factories to housing • Disassembly of equipment for reuse Examples • Conversion of old factories to housing • Disassembly of equipment for reuse](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-42.jpg)
![Chemical Recycling Of PET Molecule designed for disassembly Used as antifreeze, etc Purified, reused Chemical Recycling Of PET Molecule designed for disassembly Used as antifreeze, etc Purified, reused](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-43.jpg)
![Principle 12 • Renewable rather than depleting “Material and energy inputs should be renewable Principle 12 • Renewable rather than depleting “Material and energy inputs should be renewable](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-44.jpg)
![References • Allen and Rosselot, Pollution Prevention for Chemical Processes, 1997, John Wiley & References • Allen and Rosselot, Pollution Prevention for Chemical Processes, 1997, John Wiley &](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-45.jpg)
![GE: Defining the Principles ECI, AICh. E, ASME, SAE (2003) 1. 2. 3. 4. GE: Defining the Principles ECI, AICh. E, ASME, SAE (2003) 1. 2. 3. 4.](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-46.jpg)
![Principle 4 • Mass: use all your raw materials and concentration driving forces (10 Principle 4 • Mass: use all your raw materials and concentration driving forces (10](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-47.jpg)
![Vs. Polyacrylic acid, superabsorbent Degradable analog, polyaspartic acid Vs. Polyacrylic acid, superabsorbent Degradable analog, polyaspartic acid](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-48.jpg)
![Vs. Polyethylene, packaging Photodegradable analog Differences in cost, density, and energy intensity Vs. Biodegradable Vs. Polyethylene, packaging Photodegradable analog Differences in cost, density, and energy intensity Vs. Biodegradable](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-49.jpg)
![12 Principles Applied to Redesigned Shaw Carpet Tiles • 4. 6 billion lb carpet 12 Principles Applied to Redesigned Shaw Carpet Tiles • 4. 6 billion lb carpet](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-50.jpg)
![• 1: Inherently nonhazardous – Replaced virgin calcium carbonate filler with coal fly • 1: Inherently nonhazardous – Replaced virgin calcium carbonate filler with coal fly](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-51.jpg)
![• 3: Minimize mass and energy use – Low energy mechanical separation and • 3: Minimize mass and energy use – Low energy mechanical separation and](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-52.jpg)
![• 6: Embedded complexity is investment – Can’t make out of one material • 6: Embedded complexity is investment – Can’t make out of one material](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-53.jpg)
![• 9: Minimize material diversity – Can’t get this down due to performance • 9: Minimize material diversity – Can’t get this down due to performance](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-54.jpg)
- Slides: 54
![Green Engineering Principles and Practice Jennifer L Anthony Department of Chemical Engineering Kansas State Green Engineering: Principles and Practice Jennifer L. Anthony Department of Chemical Engineering Kansas State](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-1.jpg)
Green Engineering: Principles and Practice Jennifer L. Anthony Department of Chemical Engineering Kansas State University Adapted from presentations by E. Beckman (U. Pitt) and J. Brennecke (U. Notre Dame)
![Green chemistry is a multidisciplinary field involving fundamental sciences business law and engineering “Green chemistry is a multidisciplinary field involving fundamental sciences, business, law, and engineering. ”](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-2.jpg)
“Green chemistry is a multidisciplinary field involving fundamental sciences, business, law, and engineering. ” Green chemistry, green engineering, environmental design, sustainability, industrial ecology, natural capitalism…
![Engineering Role Environmental remediation Air Water Soil Design Engineering Role • Environmental remediation – Air – Water – Soil • Design /](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-3.jpg)
Engineering Role • Environmental remediation – Air – Water – Soil • Design / Development / Implementation – Industrial processes – Research – Classroom / Laboratory
![Balance in Design Past Balance in Design Past](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-4.jpg)
Balance in Design Past
![Balance in Design Present Balance in Design Present](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-5.jpg)
Balance in Design Present
![Balance in Design Economical vs Environmental Balance in Design Economical vs. Environmental](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-6.jpg)
Balance in Design Economical vs. Environmental
![12 Principles of Green Engineering 1 2 3 4 5 6 7 8 9 12 Principles of Green Engineering 1. 2. 3. 4. 5. 6. 7. 8. 9.](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-7.jpg)
12 Principles of Green Engineering 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Inherent rather than circumstantial Prevention rather than treatment Design for separation Maximize mass, energy, space, and time efficiency Output-pulled versus input-pushed Conserve complexity Durability rather than immortality Meet need, minimize excess Minimize material diversity Integrate local material and energy flows Design for commercial afterlife Renewable rather than depleting From Paul Anastas
![Principle 1 Inherent rather than circumstantial designers should evaluate the inherent nature of Principle 1 • Inherent rather than circumstantial “designers should evaluate the inherent nature of](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-8.jpg)
Principle 1 • Inherent rather than circumstantial “designers should evaluate the inherent nature of the selected material and energy inputs to ensure that they are as benign as possible as a first step toward a sustainable product, process, or system”
![A Case Study Acrylamide vs Nvinyl Formamide Highly toxic causes CNS paralysis 1kg A Case Study: Acrylamide vs. N-vinyl Formamide Highly toxic, causes CNS paralysis ~ $1/kg](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-9.jpg)
A Case Study: Acrylamide vs. N-vinyl Formamide Highly toxic, causes CNS paralysis ~ $1/kg Acute oral, > 1400 mg/Kg, not a neurotoxin ~ $4. 50/kg
![Acrylamide Synthesis Enzymatic route newest greenest approach Process green Product not Acrylamide Synthesis Enzymatic route newest, greenest approach Process green, Product not](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-10.jpg)
Acrylamide Synthesis Enzymatic route newest, greenest approach Process green, Product not
![NVF Production BASF Process HCN an inherent hazard raises costs Product green Process not NVF Production BASF Process HCN, an inherent hazard, raises costs Product green, Process not](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-11.jpg)
NVF Production BASF Process HCN, an inherent hazard, raises costs Product green, Process not
![Principle 2 Prevention rather than treatment it is better to prevent waste than Principle 2 • Prevention rather than treatment “it is better to prevent waste than](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-12.jpg)
Principle 2 • Prevention rather than treatment “it is better to prevent waste than to treat or clean up waste after it is formed” • Tremendous $$ spent on waste treatment, disposal and remediation; in the past not always considered in cost of plant - full cost accounting (life cycle analysis) • Usually requires extra unit operations • Industrial mindset is changing
![2 example how to prevent pollution Implementation of new technology solvent substitution eliminate 2 example: how to prevent pollution? • Implementation of new technology –solvent substitution –eliminate](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-13.jpg)
2 example: how to prevent pollution? • Implementation of new technology –solvent substitution –eliminate toxic intermediates –new reaction paths/new chemistry
![2 example how to prevent pollution Simple nolow cost solutions sloping piping 2 example: how to prevent pollution? • Simple (no/low cost) solutions – sloping piping](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-14.jpg)
2 example: how to prevent pollution? • Simple (no/low cost) solutions – sloping piping downwards to cut wash solvent use – short, fat pipes reduces drag, lower energy use – paint storage tanks white – no dead-end sample points A&R, 1997
![2 example how to prevent pollution Engineering changes raw materials pretreatment of 2 example: how to prevent pollution? • Engineering changes – raw materials; pretreatment of](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-15.jpg)
2 example: how to prevent pollution? • Engineering changes – raw materials; pretreatment of water for refinery to cut down on sludge waste – increase selectivity in reactors (reactor type, residence time, T, P, conc. , mixing, catalysis) – separation processes • • choice of mass separating agent LLE vs. distillation combined reaction/separation membrane, adsorption…. A&S 2002
![LLE vs Distillation acetic acidwater separation Acetic Acid Tb 118 2 C Dhvap LLE vs. Distillation: acetic acid/water separation Acetic Acid Tb = 118. 2 °C Dhvap](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-16.jpg)
LLE vs. Distillation: acetic acid/water separation Acetic Acid Tb = 118. 2 °C Dhvap = 24. 39 k. J/mol Water Tb = 100 °C Dhvap = 40. 6 k. J/mol - large energy cost to vaporize all that water - relative volatilities close to 1. 0, so need lots of stages
![ethyl acetate acetic acid aqueous acetic acid LLE distillation ethyl acetate acetic acid ethyl acetate + acetic acid aqueous acetic acid LLE distillation ethyl acetate acetic acid](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-17.jpg)
ethyl acetate + acetic acid aqueous acetic acid LLE distillation ethyl acetate acetic acid ethyl acetate H 2 O + ethyl acetate + acetic acid distillation ethyl acetate H 2 O + acetic acid S&H, 1998
![Combined reactionseparation C 2 H 6 C 2 H 4 H 2 C Combined reaction/separation C 2 H 6 C 2 H 4 + H 2 C](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-18.jpg)
Combined reaction/separation C 2 H 6 C 2 H 4 + H 2 C 2 H 6 C 2 H 4 H 2 C 2 H 6 - equilibrium limited to about 40% conversion C 2 H 4 H 2
![Combined reactionseparation H 2 C 2 H 6 C 2 H 4 H 2 Combined reaction/separation H 2 C 2 H 6 C 2 H 4 H 2](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-19.jpg)
Combined reaction/separation H 2 C 2 H 6 C 2 H 4 H 2 - microporous membrane - allows H 2 to pass but not C 2 H 4 or C 2 H 6 - allows close to 100% conversion - eliminates need for energy-intensive separation process
![Principle 3 Design for Separation many traditional methods for separation require large amounts Principle 3 • Design for Separation; “many traditional methods for separation require large amounts](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-20.jpg)
Principle 3 • Design for Separation; “many traditional methods for separation require large amounts of hazardous solvents, whereas others consume large quantities of energy as heat or pressure. Appropriate upfront designs permit the self -separation of products using intrinsic physical/chemical properties…. ”
![Design for Separation the Serendipitous Result Polypropylene Cap sometimes present Aluminum Ring Polyethylene Design for Separation, the Serendipitous Result…. . Polypropylene Cap (sometimes present…) Aluminum Ring Polyethylene](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-21.jpg)
Design for Separation, the Serendipitous Result…. . Polypropylene Cap (sometimes present…) Aluminum Ring Polyethylene Terephthalate Bottle Paper/adhesive Label Polyethylene Base Cup
![Recycling of PET bottles Color sort using spectroscopy green dye chemically incorporated into PET Recycling of PET bottles Color sort using spectroscopy; green dye chemically incorporated into PET](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-22.jpg)
Recycling of PET bottles Color sort using spectroscopy; green dye chemically incorporated into PET for re-use Removal of aluminum ring by electrostatic technique Shred bottles, wash to remove labels HDPE Separation of PET and HDPE by density using water
![Principle 4 Maximize efficiency products processes and systems should be designed to maximize Principle 4 • Maximize efficiency “products, processes, and systems should be designed to maximize](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-23.jpg)
Principle 4 • Maximize efficiency “products, processes, and systems should be designed to maximize mass, energy, space and time efficiency” • Mass and energy efficiency is standard Chemical Engineering optimization • Related to 8 (no overcapacity) • Related to 10 (mass & energy integration)
![4 example heat integration 170 k J cooling utility e g cooling water 4 example: heat integration 170 k. J cooling utility (e. g. , cooling water)](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-24.jpg)
4 example: heat integration 170 k. J cooling utility (e. g. , cooling water) Hot process stream in 200°C 1 kg/s Hot process stream out 30°C Cold process stream in 50°C 2 kg/s Cold process stream out 200°C 300 k. J heating utility (e. g. , steam) A&S, 2002
![4 example heat integration 30 k J cooling utility e g cooling water 4 example: heat integration 30 k. J cooling utility (e. g. , cooling water)](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-25.jpg)
4 example: heat integration 30 k. J cooling utility (e. g. , cooling water) Hot process stream in 200°C 1 kg/s Hot process stream out 30°C 60°C Cold process stream out 200°C Cold process stream in 50°C 2 kg/s 120°C 160 k. J heating utility (e. g. , steam) A&S, 2002
![Principle 5 Ouputpulled rather than inputpushed approaching design through Le Chateliers Principle therefore Principle 5 • Ouput-pulled rather than input-pushed “approaching design through Le Chatelier’s Principle, therefore,](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-26.jpg)
Principle 5 • Ouput-pulled rather than input-pushed “approaching design through Le Chatelier’s Principle, therefore, minimizes the amount of resources consumed to transform inputs into desired outputs”
![Gap uses RFID tags to keep track of amounts on shelves versus amounts in Gap uses RFID tags to keep track of amounts on shelves versus amounts in](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-27.jpg)
Gap uses RFID tags to keep track of amounts on shelves versus amounts in inventory Grocery stores use RFID to track sales and supplies of chilled food
![Principle 6 Conserve complexity embedded entropy and complexity must be viewed as an Principle 6 • Conserve complexity “embedded entropy and complexity must be viewed as an](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-28.jpg)
Principle 6 • Conserve complexity “embedded entropy and complexity must be viewed as an investment when making design choices on recycle, reuse, or beneficial disposition” • More focused on products than processes • Less complicated products can more easily be recycled • If a product is complex then it should be designed to be reused
![6 example PCs IBM PCs used to be made with 15 different types 6 example: PCs • IBM PC’s used to be made with 15 different types](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-29.jpg)
6 example: PCs • IBM PC’s used to be made with 15 different types of screws (unnecessary complexity) • Replaced with 1 type of screw • Easier to disassemble & recycle • Why not reuse computers? – make modular – replace processors, memory… – economics. . . Diana Bendz, IBM Talk at ND, 2000
![Principle 7 Durability rather than immortality It is therefore necessary to design products Principle 7 • Durability rather than immortality; “It is therefore necessary to design products](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-30.jpg)
Principle 7 • Durability rather than immortality; “It is therefore necessary to design products with a targeted lifetime to avoid immortality of undesirable materials in the environment. However, this strategy must be balanced with the design of products that are durable enough to withstand anticipated operating conditions. . ”
![Example CFCs Cx Hy Fz Clq Nonflammable Nontoxic Inexpensive Effective Stable Example: CFC’s • • • Cx. Hy. Fz. Clq Non-flammable Non-toxic Inexpensive Effective Stable](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-31.jpg)
Example: CFC’s • • • Cx. Hy. Fz. Clq Non-flammable Non-toxic Inexpensive Effective Stable
![Example CFCs Cx Hy Fz Clq Nonflammable Nontoxic Inexpensive Effective Stable Example: CFC’s • • • Cx. Hy. Fz. Clq Non-flammable Non-toxic Inexpensive Effective Stable](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-32.jpg)
Example: CFC’s • • • Cx. Hy. Fz. Clq Non-flammable Non-toxic Inexpensive Effective Stable • Long-lived, migrate to upper atmosphere • UV-induced fragmentation in upper atmosphere leads to ozone depletion
![Principle 8 Meet Need Not Excess design for unnecessary capacity or capability e Principle 8 • Meet Need, Not Excess “design for unnecessary capacity or capability (e.](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-33.jpg)
Principle 8 • Meet Need, Not Excess “design for unnecessary capacity or capability (e. g. , “one size fits all”) solutions should be considered a design flaw” • Don’t over design things; keep contingency factors low • Extra size means wasted material and energy
![8 example whole industry overcapacity Global auto industry has 80 million vehiclesyr capacity 8 example: whole industry overcapacity • Global auto industry has 80 million vehicles/yr capacity](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-34.jpg)
8 example: whole industry overcapacity • Global auto industry has 80 million vehicles/yr capacity for market of <60 million/yr (“Where Optimism Meets Overcapacity”, NYTimes, Oct. 1, 1997) • U. S. 2002 plant utilization ~ 75% (Industry Week)
![Principle 9 Minimize material diversity options for final disposition are increased through upfront Principle 9 • Minimize material diversity “options for final disposition are increased through upfront](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-35.jpg)
Principle 9 • Minimize material diversity “options for final disposition are increased through upfront designs that minimize material diversity yet accomplish the needed functions”
![Examples Automobile design use single materials rather than alloys metal and polymeric Examples • Automobile design: use single materials rather than alloys (metal and polymeric) •](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-36.jpg)
Examples • Automobile design: use single materials rather than alloys (metal and polymeric) • Additives; create multi-functional additives rather than packages, incorporate additive functionality into polymeric backbone (dyes, flame retardants) • Pigments; can pigments be switched “on” and “off”; can changes in pigment physical properties allow for variety of colors?
![Principle 10 Integrate Material and Energy Flows design of products processes and systems Principle 10 • Integrate Material and Energy Flows “design of products, processes, and systems](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-37.jpg)
Principle 10 • Integrate Material and Energy Flows “design of products, processes, and systems must include integration and interconnectivity with available energy and materials flows” • • • Make use of what you’ve got available Heat integration (example 4) Mass integration (ethanol example) Large scale (Kalundborg industrial park) In process or on site
![10 example Ethanol for Gasoline Ethanol from fermentation of biomass 15 wt 10 example: Ethanol for Gasoline • Ethanol from fermentation of biomass > ~15 wt%](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-38.jpg)
10 example: Ethanol for Gasoline • Ethanol from fermentation of biomass > ~15 wt% kills yeast • distill ethanol; entrainer to break azeotrope – large energy use – benzene (carcinogen) common entrainer • add purified ethanol to gasoline
![10 example Ethanol for Gasoline Alternative Direct contact of fermentation broth with gasoline 10 example: Ethanol for Gasoline Alternative • Direct contact of fermentation broth with gasoline](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-39.jpg)
10 example: Ethanol for Gasoline Alternative • Direct contact of fermentation broth with gasoline Gasoline + ethanol CO 2 Fermenter Solids; animal feed LL extractor Strong fermention broth Gasoline Weak fermention broth
![10 example Kalundborg Industrial Park Novo Nordisk sulfuric acid plant sulfur refinery waste treatment 10 example: Kalundborg Industrial Park Novo Nordisk sulfuric acid plant sulfur refinery waste treatment](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-40.jpg)
10 example: Kalundborg Industrial Park Novo Nordisk sulfuric acid plant sulfur refinery waste treatment Lake fish farm fjord greenhouses steam gas cooling water wastewater power plant Plaster board plant gypsum fly ash district heating A&S, 2002
![Principle 11 Design for commercial afterlife To reduce waste components that remain functional Principle 11 • Design for commercial afterlife “To reduce waste, components that remain functional](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-41.jpg)
Principle 11 • Design for commercial afterlife “To reduce waste, components that remain functional and valuable can be recovered for reuse and/or reconfiguration”.
![Examples Conversion of old factories to housing Disassembly of equipment for reuse Examples • Conversion of old factories to housing • Disassembly of equipment for reuse](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-42.jpg)
Examples • Conversion of old factories to housing • Disassembly of equipment for reuse of components • Creation of “plastic lumber” from used polymeric packaging material (molecular reuse)
![Chemical Recycling Of PET Molecule designed for disassembly Used as antifreeze etc Purified reused Chemical Recycling Of PET Molecule designed for disassembly Used as antifreeze, etc Purified, reused](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-43.jpg)
Chemical Recycling Of PET Molecule designed for disassembly Used as antifreeze, etc Purified, reused to make PET
![Principle 12 Renewable rather than depleting Material and energy inputs should be renewable Principle 12 • Renewable rather than depleting “Material and energy inputs should be renewable](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-44.jpg)
Principle 12 • Renewable rather than depleting “Material and energy inputs should be renewable rather than depleting” • Don’t want to deplete our natural resources • Need resources to be there for future generations • Energy: solar, wind, hydroelectric, geothermal, biomass, hydrogen (fuel cells)
![References Allen and Rosselot Pollution Prevention for Chemical Processes 1997 John Wiley References • Allen and Rosselot, Pollution Prevention for Chemical Processes, 1997, John Wiley &](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-45.jpg)
References • Allen and Rosselot, Pollution Prevention for Chemical Processes, 1997, John Wiley & Sons, Inc. • Allen and Shonnard, Green Engineering, 2002, Prentice-Hall • Seader and Henley, Separation Process Principles, 1998, John Wiley & Sons, Inc. • Segars et al. , ES&T, 2003, 37, 5269.
![GE Defining the Principles ECI AICh E ASME SAE 2003 1 2 3 4 GE: Defining the Principles ECI, AICh. E, ASME, SAE (2003) 1. 2. 3. 4.](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-46.jpg)
GE: Defining the Principles ECI, AICh. E, ASME, SAE (2003) 1. 2. 3. 4. 5. 6. 7. 8. 9. Engineer processes and products holistically, use systems analysis, and integrate environmental impact assessment tools Conserve and improve natural ecosystems while protecting human health and well-being Use life-cycle thinking in all engineering activities Ensure that all material and energy inputs and outputs are as inherently safe and benign as possible Minimize depletion of natural resources Strive to prevent waste Develop and apply engineering solutions, while being cognizant of local geography, aspirations and cultures Create engineering solutions beyond current or dominant technologies; improve, innovate and invent (technologies) to achieve sustainability Actively engage communities and stake-holders in development of engineering solutions
![Principle 4 Mass use all your raw materials and concentration driving forces 10 Principle 4 • Mass: use all your raw materials and concentration driving forces (10](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-47.jpg)
Principle 4 • Mass: use all your raw materials and concentration driving forces (10 example) • Energy: heat integration • Space: small cars • Time: “just-in-time” manufacturing (operations research/scheduling) – supply availability big issue
![Vs Polyacrylic acid superabsorbent Degradable analog polyaspartic acid Vs. Polyacrylic acid, superabsorbent Degradable analog, polyaspartic acid](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-48.jpg)
Vs. Polyacrylic acid, superabsorbent Degradable analog, polyaspartic acid
![Vs Polyethylene packaging Photodegradable analog Differences in cost density and energy intensity Vs Biodegradable Vs. Polyethylene, packaging Photodegradable analog Differences in cost, density, and energy intensity Vs. Biodegradable](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-49.jpg)
Vs. Polyethylene, packaging Photodegradable analog Differences in cost, density, and energy intensity Vs. Biodegradable analog
![12 Principles Applied to Redesigned Shaw Carpet Tiles 4 6 billion lb carpet 12 Principles Applied to Redesigned Shaw Carpet Tiles • 4. 6 billion lb carpet](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-50.jpg)
12 Principles Applied to Redesigned Shaw Carpet Tiles • 4. 6 billion lb carpet to U. S. landfills annually • Redesigned for recycle – Nylon 6 or Nylon 6, 6 carpet – PVC plastisol backing replaced with branched LDPE – Can disassemble and recycle both nylon and backing • 2003 Presidential Green Chemistry Challenge winner
![1 Inherently nonhazardous Replaced virgin calcium carbonate filler with coal fly • 1: Inherently nonhazardous – Replaced virgin calcium carbonate filler with coal fly](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-51.jpg)
• 1: Inherently nonhazardous – Replaced virgin calcium carbonate filler with coal fly ash – Replace PVC and phthalate plasticizer with (mostly) branched LDPE (metallocene catalyst important) – Less toxic flame retardant (not, Sb 2 O 3, or proprietary aluminum trihydrate, what is it? ) • 2: Prevent waste – Recycle everything – Penalized by CPG under RCRA 6002 when introducing NEW recyclable material !!!
![3 Minimize mass and energy use Low energy mechanical separation and • 3: Minimize mass and energy use – Low energy mechanical separation and](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-52.jpg)
• 3: Minimize mass and energy use – Low energy mechanical separation and size reduction for recycle – Nylon sent for depolymerization (Honeywell)? • 4: Efficiency – Extrusion coating requires less energy than radiant gas fusing (VOCs) – New tiles are 40% lighter (shipping!) – Telescoping boxes • 5: Output pulled rather an input pushed – NA since replacement application
![6 Embedded complexity is investment Cant make out of one material • 6: Embedded complexity is investment – Can’t make out of one material](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-53.jpg)
• 6: Embedded complexity is investment – Can’t make out of one material due to performance – Separating and recycling next best thing • 7: Durability, not immortality – These materials are immortal – OK because can recycle forever? • 8: No unnecessary capacity – NA since replacement market – Problem if try to implement for regular carpet market
![9 Minimize material diversity Cant get this down due to performance • 9: Minimize material diversity – Can’t get this down due to performance](https://slidetodoc.com/presentation_image_h/d7efe0d32b997205880829bffa3e33f0/image-54.jpg)
• 9: Minimize material diversity – Can’t get this down due to performance criteria – Using same backing for multiple products is an example of this • 10: Mass/energy integration – Cooling water in plant in closed loop – Recycling of polymers closes the loop • 11: Design for commercial afterlife – Recycling so don’t need to worry about afterlife • 12: Renewable rather than depleting – Materials used are not renewable – Energy used is not renewable – …but company has invested in a wind farm…
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