Thermodynamic Analysis of Manufacturing Processes

Stephanie Dalquist; Jeffrey Dahmus; Alex Thiriez; Alissa Jones; Matthew Branham; Dusan Sekulic, U. Kentucky; Timothy Gutowski

Sponsors: National Science Foundation, SKF

Remanufacturing

Elsa Olivetti, MIT Dept. of Material Science & Eng.; Steve Graves, MIT Sloan School; Timothy Gutowski

Sponsor: MIT Energy Initiative

Recycling

Malima Wolf; Jeffrey Dahmus; Dominic Albino; Phillip Bohr, TU Berlin; Ante Mrkonjic, U. Stuttgart; Brianne Metzger; Timothy Gutowski

Sponsors: National Science Foundation, Hewlett Packard

Collaborators: Roger Morton, Axion Ltd. U.K.; Mike Mankosa, Eriez

Production and Efficiency

Jeffrey Dahmus; Suganth Kalakkad; Arnaud Uzabiaga, Ecole Polytechnic, Paris; Olivia Grehler, BU; Timothy Gutowski

Environmental Life Style Analysis

Amanda Taplett, Anna Allen, Amy Banzaert, Rob Cirinciore, Christopher Cleaver, Stacy Figueredo, Susan Fredholm, Betar Gallant, Alissa Jones, Jonathan Krones, Barry Kudrowitz, Cynthia Lin, Alfredo Morales, David Quinn, Megan Roberts, Robert Scaringe, Tim Studley, Sittha Sukkasi, Mika Tomczak, Jessica Vechakul, Malima Wolf, Timothy Gutowski

Environmental Analysis of Manufacturing Processes

Jeffrey Dahmus, Stephanie Dalquist, Alex Thiriez, Timothy Gutowski

Sponsor: National Science Foundation

Collaborators; Jung-Hoon Chun, MIT; John Sutherland, Michigan Tech; Marquita Hill, University of Maine, Orono

The focus of this project is on modeling the environmental performance of manufacturing processes for use in Design for Environment (DfE) guidelines. The project addresses eight mainstream manufacturing processes: 1) machining, 2) grinding, 3) electrical discharge machining, 4) abrasive water jet machining, 5) sand casting, 6) die casting, 7) injection molding, and 8) advanced composites autoclave processing. These processes are being evaluated for energy and material usage, solid (hazardous and non-hazardous) wastes, and air and water emissions. Equipment-level models are developed and compared to national statistics for typical factory configurations. These models will then be used to compare the environmental performance of alternative processes, alternative product designs and process plans, and proposed new process developments. This information is needed in Life Cycle Analysis (LCA) and to more clearly focus attention on manufacturing process development needs for a sustainable future.

Production, Use and Efficiency

Jeffrey Dahmus, Timothy Gutowski

In this project, historical data for industrial efficiency has been reviewed and compared with trends in production and use. The results show that in almost every case, use and production exceed efficiency gains. This effect, call the “rebound” effect or Jevons Paradox appears to be not the exception, but the rule. The few exceptions that can be found in history, are always accompanied by an “external value proposition” e.g. regulation and/or price hike. The results of this analysis cast significant doubt on the popular strategy of “eco-efficiency” to control our environmental load, but also suggest strategies and modifications that can result in real environmental improvement.

A Permit Market Approach to Foster Sustainable Manufacturing of Electrical and Electronic Equipment

Philipp Bohr, Timothy Gutowski

In the course of this project, an analysis of plausible regulatory incentive schemes to foster sustainable manufacturing of electrical and electronic equipment is conducted. The main emphasis is on closing material loops via reuse, remanufacturing and recycling. This will be complemented by a balanced accounting for related environmental aspects and considerations of eco-efficiency.

Recycling Index for Inkjet Printers

Brianne Metzger, Timothy Gutowski

Sponsor: Hewlett Packard

Collaborators: Tim Frederick and Erin Gately, HP

The thrust of this project is to develop a new design tool to evaluate inkjet printers and similar products for compliance with new take-back regulations in the European Union. The design tool includes a recycling index as well as a cost model to evaluate the potential impact of design features on take-back associated costs.

Benign and Efficient Materials

Olivia Grebler, Timothy Gutowski

In this project we look at materials substitution solutions to environmental problems, and assess their environmental improvement and efficiency in performance from a historical perspective. Topics include; paper bleaching, gasoline additives, refrigerants, plating metals, coal, insecticides, and cleaning solutions.