Transcript Technology and Environment

Chemical Engineering: new paradigms and environmental syllabus
F.Gutiérrez, M.A.Sanchiz, M.T.Hernández, E.Atanes
DPT. QUIMICA INDUSTRIAL Y POLIMEROS, TECHNICAL UNIVERSITY (UPM), MADRID - SPAIN
2) Evaluate problems to obtain indexes for specific activities
Re-orient ChE education to promote the new paradigm of sustainability, moving
beyond basics and environmental engineering, and translate `abstract ideas´ into
definite problems where engineering´ science can be put into action (solving skills)
Manufacturing industry is concerned with processing materials and the laws of science
govern these operations. Two consecuences follow from this: raw materials and energy
is needed to effect transformations and waste is produced.
Environmental problems are systemic and thus require a `systems approach´, at different levels, that
provides a holistic view of connections between industrial practices and human activities, making them
easier to identify and solve: key issues include the use of resources, ecological and human health, and
environmental equity (both intergenerational and intersocietal)
The best that can be achieved is to minimize the use of resources and reduce waste
production; and the 1st step in this attempting is to describe the situation that currently
exist because this is the basis against which any future improvements will be judged.

INPUTS
1) Define sustainability scores (social, environmental & economical)
Increasing economy and quality of life, while decreasing resource consumption
and pollution:


Ecological risk assessment: from defining the sources to estimating effects
OUTPUTS
SYSTEM
MEDIUM
Usable products
and coproducts
Raw materials
Urban
Air emissions
Atmosphere
Manufacturing
Water effluents
Hydrosphere wastewaters and eutrophication
Uncoupling between a growing welfare and the use of nature (factor x)
Targets for improvement to be operationalized by appropiate strategies
water resources, raw
(organics, ions NP) materials and energy
(consumption);
toxics to air, water, soil
(AH, pesticides, metals)
Solid wastes
Use, recycle
and waste m.
Life cycle stages
landfills,
incineration
(solid wastes)
Litosphere
Other releases
(waste heat)
Global
photo-chemical and acidification
radiative effects
(CO,VOCs,NOx,SOx,NH3) (CO2,CH4,N2O, CFCs)
Energy/fuels
Water
Regional
Raw materials
adquisition
Life cycle inventories: taught at level of engineering fundamentals (mass and energy balances)
Weighting of scores (scientific, political & public perception)
Interrelatioship of safety, health and environment, through the concept of exposure
Inputs (Ik)
Energy (Ek)
Sustainable development: huge extension of the
spatial, temporal and biological scales, including the
social-economic-political systems of our society, and
the values, norms and ethics on which they are based
Intensity of
exposure
Safety
economy
quality of life
Outputs (Pj)
Step
(k)
LITOSPHERE
BIOSPHERE
sk: normalized stream Ik/Pj Ek/Pj Wk/Pj
total system: s= (Pk+1sk+Pjsk+1)/Pj
Construction and operation of systems:
Ecobalance:
Sk
Sk+1
Pk+1
Construction
Ik·VI,i·fI,j +Ek·VE,i·fE,j -Pj·VPj,i -Wk(-Vw,i)fw,j= 0
Pj
Linear (non-recurring network)
VS,i: ecovector, EL(i)/kg or kJ (S)
Pollution index (total load per unit mass of product):
(WC, kg)
(equipment and
buildings)
INPUTS
(the ability of the Earth to sustain future generations might be in
jeopardy, as a results of the exponentially increasing numbers of
humans beings, the emission of pollutants, and the exhaustion of
non-renewable energy and raw material resources).
use of resources
and pollution
Multimedia
approach
HYDROSPHERE
Mass balance: Ik= Pj+Wk
Wastes (Wk)
ATMOSPHERE
soil & groundwater
(diffuse pollution)
WASTES
Processing
(Y, years)
fS,j: partitioning (e.g. Pj /P)
VPj = 1/Pj ·i k (SkVSk,i)·fSk,k+1
(WP, kg/y)
PRODUCTS (P, kg/y)
V(kgW/kgP)= 1/P·(WP,i+W C,i/Y)
Health
Characterization and valuation of impacts
Environment
Duration of exposure
Score (kgeq) for category indicator e in reference situation r :
Se,r = sxi fe,i,x,s · Vi,x,s,r
Problem analysis (sources, effects) and solutions (options, actions) going “up the pipe” from the discharge to the
production processes, even further to the supply operations, and ultimately to the design of products themselves;
the systems using the inputs and creating the wastes are analized for opportunities to reduce them by improving
efficiency, training, purchase or other, and these are implemented based on technical and economical feasibility,
while CP or P2 have expanded to include the full life cycles and the use of whatever method works
Environmental index (person-yr eq.):
EI=  I [i (VPj,i·fe,i )/Se,r]·fI
fI : weighting factor, e.g. priorities as cocient between current (PE)
and targeted impacts (PET), normalized per person-yr
With increasing population and material standard of life, the demand of products of humankind seem to increase by a factor of 5 or
more over the next 50 years (the task is to increase efficiency to fulfil these needs, i.e. reduce the demand, resource
consumption and impacts per service provided).
Polution prevention (P2): focus in use of materials, processes or practices that mitigate the pollutants in origin, and refers to specific actions
by individual firms, rather than collective activities of the industrial system as a whole (industrial ecology).
Industrial ecology studies the interaction between industrial and ecological systems, with the goal of changing its linear nature (raw materials,
products and wastes) to a cyclical system (where processes are integrated and by-products are optimized by reusing wastes
as energy or material inputs for another products).
Design for environment (DfE), Life cycle design (LCD) and similar initiatives, are the system-oriented strategies to sustainable products based
on Life Cycle concepts and the “design for X” approach, where X represent a downstream design consideration (eg. reliability).
Substantial activity is directed at the production levels using tools as LCA/LCD and strategies such as P2 (micro, meso & macro-scale options);
but current approaches rely heavily on `engineered-technical solutions´ to enviro-problems: changing industrial systems must
be balanced properly with changes in social patterns.
- From a sole emphasis upon technological measures, to a broader scale perspective
wich also encompases non-tech measures
- From consideration of environmental aspects of the manufacturing process, to also
considering the entire life cycle of a product.
European Reduction PET - 2004
PE (1994) (estimate for sustainability)
Impact category
Characterization model
Unit
World
Resource depletion
Land competition
Climate change
Stratospheric ozone
Tropospheric ozone
Acidification
Eutrophication
Ultimate world reserves and yearly extraction
Temporary loss of land (economic processes)
Global warming potentials (100 yr-horizont)
Ozone depletion potentials ( 20 yr-horizont)
Photochemical potentials (l/h NOx scenario)
Marginal changes in potential impacts of all
ecosystems or where threshold is exceeded
(terrestrial and aquatic eutrophication)
Human toxicity
Fresh water acuatic ecotoxicity
Marine acuatic ecotoxicity
Terrestrial ecotoxicity (industrial & agro soil)
kg Sbeq
km2 ·yr
kg CO2,eq
g CFC-11,eq
kg C2H4,eq
kg SO2,eq
kg NOx,eq
kg PO43-eq
kg 1,4-DCB,eq
1,6·1011
1,2·108
4,1·1013
8200
4% (65%)
6,0·1011
0,081 100%
9,2·1010
25
20% (50%)
3,2·1011
74
34% (90%)
3,9·1011
120
29% (90%)
6,1·1010
5,7·1013 HTW(m3): 52000
3
9
1,8·1012 HTA (m 3): 3,1·10
4,8·1011 ETW (m ): 350000
17% (85%)
1,3·1011
(1995)
- From pollution control and waste handling technologies after its generation, to more
proactive process integrated prevention (cleaner production, multimedia cross effects
and reduction approach at source, specially diffuse non-point-sources)
[ Ne,r (r/Pj) = Se,j /Se,r ]
Vi,x,s,r (kg/r): interchange of substance i to compartment x in the region s for reference situation r
fe,i,x,s (kgeq/kg): characterization factor related to indicator e for substance i emitted to compartment x in the region s
Toxicity potentials
(organic, halogenated,
PAHs, pesticides,
inorganic, metals)
dichlorobencene
20 yr TH
fI
2,9
2,0
10
10
6,7
3) Select and implement solutions
Yielding options for the redesign of a process or a product, in combination with cost and technological feasibility
Mathematical procedures for identification of options and the expertise from process technologists and designers, are the
basis of solution tools for continuous environmental improvements of processes and products (efficiency & eco-design)
Design checklists and matrices are used to address sistematically environmental issues and to study interactions with the life cycle
(e.g. BREFs, ranking systems, dominance or marginal analysis, products)
Summary of concepts and paradigms
Environmental technologies (BAT)
Clean or cleaner technologies (CP)
Sustainable development
(S)
PC vs PP
x
.
.
x
.
x
TE & NT
x
.
x
.
x
x
PE & PU
.
.
x
.
x
x
SM - MM
x
.
.
x
.
x
Aspects
Traditionally BAT are considered only pollution control (PC) technical (TE) measures (end-of-pipe techs), that have
generally the inconvenients of shifting pollutants from one to another media (SM), and also aditional cost of production.
CT (cleaner production) can be viewed as a conceptual and procedural approach to industrial production (or process
oriented, PE) with the objective of the minimization or prevention (PP) of risks to humans and to the environment [primary
emphasis ongoing to systematic and integrated source reduction approach (MM), but oriented to production organizations].
The sustainability (S) paradigm, doesn´t omit consumption and production structures at the societal level (attitudinal and
other non technical, NT, and product oriented, PU, measures), within a broader policy concept approaching on the entire
organization of society that involves industrialists, government authorities, educators and citizens to ensure sustainable
societies. Such an approach in relation to water (or air, or soil) pollution should be focused upon both of the reduction of
emissions from industrial point sources, and non point sources, with a multimedia approach (MM).
demand
product (DfE,LCA)
production
(process integration)
elimination
source reduction
•
recycle
process (CP)
treatment
•
emission
disposal
Social-demand side:
Technical-production side
-
-
control of the population grownt
downsizing (level-quality of life)
services instead of products
Population
size
P
+
Consumption
levels
L
+
process optimization
new technologies
product design
Production
efficiency E
savings
P: number of individuals (cap)
Total effect = (P  L)  (E
L: production (GDP/capita)
E: material or energy intensity (kg or kJ per unit of economic value, GDP)
I : specific impacts (sum of environmental effects / unit of resources used)
Source
reduction &
eco-design
[social, chemicals,
processes,
equipments &
management actions]
Recovery
(reuse,
reclamation,
recycling)
[metals & electricals
(lamps, batteries),
ceramics & glasses,
paper & textils,
polymers & rubbers,
oils, solvents &
baths, water, etc]
Control,
treatment
(environmental
technologies) &
discharge
(disposal,
dilution)
+
Cleaner
alternatives I
Classification of environmental innovations.- Assess and weighting
technical and economic performance of opportunities to save materials,
energy and water, and to reduce emissions, effluents and wastes, form
compounded-priority classes ranking from radical to low efficient techs
MINIMIZATION HYERARCHY: Improvement measures can follow the
demand-supply chain at the different hierarchical-synergic levels:
 Demand of products can be reduced
 Prod´s are redeveloped -ecodesign- to
decrease production and use efforts
(volumes, energy and/or hazardous)
 Production can be re-engineered to
reduce process efforts by integration
(e.g. industrial symbiosis)
 Individual processes are re-designed
using cleaner techs to decrease its
environmental interchanges and
treatment efforts.
Integrated pollution prevention and control:
OPTIONS
INTERNAL
EXTERNAL
PREVENTIVE
Source reduction & eco-design:
elimination, clean/er product-ion/s,
fugitive emissions
Selection, Recovery, Subproduct
exchange
Effluent control (end of pipe),
abatement technologies
Waste treatment, clean-up techs
(remediate existing problems)
 I)
CORRECTIVE
*Policy & consumer customs (reduce, reutilization, resource consumption, water and energy)
*Product, process & management innovation (production efficacy & quality)
-Product substitution, composition & use (solvents, plaguicides, plastics, cleaners, coatings & colours, aditives, etc)
-Technology and material changes (alternative processes, optimization of operating conditions, control, improved equipment,
substitution/purification of reagents, solvents, catalysts, etc), internal recycle, integration (pinch analysis, energy and water)
-Good practices (human and organizative aspects, working routines, recording, handling, segregation, maintenance, loss
prevention: containment, sumps and venting, spills, leaks and fugitive emissions in vessels, pumps, pipes and valves)
-Energy issues (conservation, efficiency, diversification & clean combustion technologies; mobile and stationary sources;
greenhouse potential/ energy unit/ GNP)
Sectorial (case-study) approach (industrial environmental engineering): Machining & metal working, Metal plating & surface
finishing, Painting, coating & removal, Solvents, refrigerants, antifreezers & propellents, Construction & demolition,
Aluminum, Iron & steel, Petroleum & refining, Food, Pharmaceuticals, Pulp & paper, Energy & electric utilities, etc
-Design for recycling, cars (e.g.PP), bottling & packing, ...
-Primary (reuse) (mechanical, mixed-wastes) & secondary (physical-selection, reclamation)
-Terciary (chemical transformation: pyrolisis, solvolisis)
Scope of organizational
concern
Society
c enviro-compartment (admissible concentrations, m
 SWi /P
Solid wastes
air,water,soil/mg waste)
SW: amount of solid waste released (excluding the toxic)
For each technical aspect and life-cycle phase, values are measured before and after an improvement
and they are reported as percentage changes and weighted averages for the matrix rows and columns
Global efficiency index =
Improvements in productivity, quality and product mix / technical environmental improvement
Chemical management services (CMS) rather
than physical products or volume as basis of
supplier compensation by: dematerialization,
use intensification, life extension, ecodesign,
and, in general, alternative f. fulfilment (AFF)
Product strategies into increased
design spaces: critical analysis of
the current solutions, the underlying
needs, the way they are fulfilled, and
generate innovative concepts: four
hieralchical stages of eco-design and
innovation; i.e. cars
- Product improvement: fuel economic engines, catalitic converters
- Redesign product: weight, material diversity, ease disassembly
- Fulfilment of needs in a different way: hybrid cars, transport functions
- Sustainable mobility: rethinking the whole concept (new infrastructure)
ENVIRONMENTAL PERFORMANCE EFFORTS AT DIFFERENT LEVELS
5
SD
4
One manufacturer (X products)
Policy programs, regulations
IE
Systems engineering
EMAS
Single product life
cycle
disposal
use
3
PP

(1&2)
Physical,chemical &biological processes (to reduce volume, toxicity or mobility of hazardous)
(3)
planning
1 CP
EAc
R
manufacturing
use
disposal
system/product life cycle
The challenge: move towards
more holistic thinking and focus
on the life cycle performance
Product design (DfE)
Life cycle (LCA,LCS)
Ecolabeling (Elb)
2
manufacturing
Specific pollutant, environmental sub-system (simple media) approach (e.g. SOx abatement from combustion or sulphuric acid
industries have different pollution prevention strategies, but similar control technologies).
-Clean air technologies (metals and particulates, acid gases and VICs, methane, N2O and VOCs) & Atmospheric
dispersión (micrometeorology, stack design)
-Wastewater, physicochemical (off-site) and specific waste (in-site & mobile) treatment facilities (liquid &
industrial wastes; suspended, DBO, organic,AOX & inorganics, N,P, pathogenous)
-Incineration (combustibles); Landfilling (solid wastes) & Soil and aquifer remediation (in-situ/on/off-site);
geology, hidrology; diffuse pollution (non-point; agriculture, lakes, roads): nutrients (chemical fertilizers,
nitrates) and toxics (hydrocarbons, pesticides, bioaccumulation), ameliorating effects/symptoms.
Emissions to air
category e
emission (Vi) and equivalent factors (fe: GWP,ODP,POCP,AP,NP)
and waterborne
Polluted media (critical-volumes approach, m3/P); Vi,Efc,i: emission
Hazardous
ic Vi [Ef(e)c,i
eco-toxicological/ human equivalency factors for substance ith in the
and toxics
+Ef(h)c,i] /P and
th
3
X manufacturers
-Valorization (other): Thermal (waste to energy), Composting, Land and Construction uses
Phase separation: dust collection (inertials, filters), sedimentation, floculation, precipitation, filtration, flotation, etc.
Components: scrubbing(wet,dry,regenerative), adsorption, condensing, membranes, ion-ex., extraction, distillations (stripping).
Destructive: neutralization, digestion (activated sludges, biological beds, trickling filters, RBCs, natural systems), thermal,
chemical & redox (catalytic, photolytic, electrolytic), use of electron receptors other than oxigen.
Inertization & sludge treatment: immobilization (stabilization, fixation, solidification, vitrification), dewatering.
Mi, mi: materials introduced in the cycle and the product
Ei, ei: introduced vs useful energy obtained by resources
Aux, P: aux.material used vs amount of product obtained
W:
water intensity (quantity used per product unit)
Se= i Vi fe,i :
scores by a problem oriented approach with
Product-service systems, p.stewardship:
Address sustainable consumption patterns
by providing customer satisfaction through
systems integrating products and services
with net reduction of the use and impacts
during life cycle (i.e. supplier of paints)
Pollution prevention in the CPI through clean process design merged with the interpretation
phase of the life cycle assessment: LCA tool + system modelling & optimization techniques
innovation
Quantification of efficiencies and intensities in production life cycles
( resources – transport – processing – distribution – use – post-product life )
mi /Mi
ei / Ei
Auxi /P
W/P
Se/P by impact
Raw materials
Energy cycle
Auxiliaries
and Water

company lifetime civilization span
Scope of temporal concern
Process oriented tools (production systems): Environmental technology, clean production (CP, narrow sense),
environmental accounting (EAc) & Pollution prevention (PP) and recycle (R), system thinking, planning process.
Product oriented tools (product systems): Ecodesign (DfE), life cycle concepts (LC), Eco-labeling (Elb).
(4&5) System levels (environmental, economic, social): Industrial ecology (meso) & Sustainable development (macro);
Company: environmental management and auditing (EMAS), Industrial complex level (system symbiosis), long term.
Solution through design form the core of engineering, linking `hard sciences´ with the new paradigms, using systematic tools
(operative conditions, reaction pathways, process integration, substitute materials) , problem and function directed courses around concrete
examples (solving skills, best selection procedures), plus institutional-ethical factors in a holistic approach from housekeeping
(high-ROI) and molecular levels to production systems and civilization spans (integrated programs and case-studies).
- Information about CP/P2 and DfE constitutes the largest collection in the world, including extensive training materials and
resources (manuals, cases, tools and software), and they ere almost all free through organizations, internet and specific sources:
USEPA and EEA, Green engineering & GCES, GreenPro, WAR, SWAMI, PARIS-II, EDIP, P2PAYS, CEIDOCT, P2/CP collection (CDROM), etc.