Table Of ContentIndustrial and Manufacturing J Green Design and
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Written by an educator with close to 40 years of experience in developing and teaching design a
and manufacturing courses at the graduate and undergraduate levels, Green Design and
Manufacturing for Sustainability integrates green design and manufacturing within the frame-
Manufacturing
work of sustainability, emphasizing cost, recyclables, and reuse. It includes the analytical tech-
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niques for cost minimization, reduction of material waste, and the reduction of energy consumption
during the manufacturing process.
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The text introduces sustainability principles, then goes on to detail all aspects of green design, n for Sustainability
economics, feasible material selection, and relevant and efficient manufacturing processes. It u
highlights techniques such as life cycle cost assessment, reuse, and recyclables and showcases
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them with examples and problems solved. a
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In addition, the author defines green mechanical design as the selection of materials, processes,
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and geometry that satisfies specified and implied environmental requirements. He stresses that for u e
sustainability, social, environmental, and economic development must be integrated and balanced.
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Developed to bring environmental issues into the basics of mechanical component design n
and manufacture, the textbook brings together principles of environmentally conscious design
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and sustainable manufacture in a format with examples and problems that can be adapted for
undergraduate classes.
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The carefully selected range of examples and exercises presented makes it easier to adopt into the
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engineering curriculum suitable for senior-level undergraduates as well as first-year graduates. g
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Nand K. Jha
K14557
an informa business
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K14557 mech rev.indd 1 11/10/15 4:27 PM
Green Design and
Manufacturing
for Sustainability
Green Design and
Manufacturing
for Sustainability
Nand K. Jha
CRC Press
Taylor & Francis Group
6000 Broken Sound Parkway NW, Suite 300
Boca Raton, FL 33487-2742
© 2016 by Taylor & Francis Group, LLC
CRC Press is an imprint of Taylor & Francis Group, an Informa business
No claim to original U.S. Government works
Version Date: 20151109
International Standard Book Number-13: 978-1-4822-8238-2 (eBook - PDF)
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Contents
Preface xxvii
Acknowledgments xxxi
Author xxxiii
1 Introduction to Sustainability, Principles, and Its Effect on Design and
Manufacturing 1
1.1 Introduction ...............................................................................................................................................1
1.1.1 Water Has No Substitute .........................................................................................................3
1.1.2 Sustainable Water Management ............................................................................................3
1.1.3 Recycling Technologies ...........................................................................................................3
1.1.4 Getting Started .........................................................................................................................4
1.2 Design for Sustainability ..........................................................................................................................6
1.2.1 Sustainable Initiatives ..............................................................................................................6
1.2.2 Cleaner Production ..................................................................................................................7
1.2.3 Design for Sustainability .........................................................................................................7
1.3 Objectives for Green Design ....................................................................................................................7
1.4 Rubicon of Engineering Design ...............................................................................................................8
1.5 Some Green Design Methods and Tools ................................................................................................8
1.5.1 Systems Thinking .....................................................................................................................8
1.5.2 Environmental Life Cycle Assessment (LCA) .....................................................................8
1.5.3 Material Flows and Cycles ......................................................................................................8
1.5.4 Green Indices ............................................................................................................................8
1.5.5 Design for Disassembly and Recycling Aids ........................................................................9
1.5.6 Risk Analysis .............................................................................................................................9
1.6 Mathematical Representations of Sustainability ..................................................................................9
1.7 Material Selection and Label Advisors ...................................................................................................9
1.8 Green Power Generation ........................................................................................................................10
1.9 Net Energy Analysis ................................................................................................................................10
1.10 Greenhouse Gas Emission Rates ...........................................................................................................11
1.11 Carbon Accounting in Corporations ...................................................................................................11
1.11.1 Environmental Full Cost Accounting Methodologies .....................................................11
References .............................................................................................................................................................13
Bibliography .........................................................................................................................................................13
v
Section I Industrial Ecology and Sustainability
2 Industrial Ecology and Sustainability 17
2.1 Introduction .............................................................................................................................................17
2.2 Global Warming Potential .....................................................................................................................21
2.2.1 Basic Principles .......................................................................................................................21
2.3 Material Balances .....................................................................................................................................25
2.4 Bases and Units ........................................................................................................................................25
2.5 Total Mass and Composition .................................................................................................................25
2.6 Continuous Processes .............................................................................................................................26
2.7 Blending ....................................................................................................................................................27
2.8 Drying .......................................................................................................................................................27
2.9 Energy Balances .......................................................................................................................................27
2.10 Heat Balances ...........................................................................................................................................28
2.11 Other Forms of Energy ...........................................................................................................................30
2.12 Flow Chart ................................................................................................................................................31
2.12.1 Method for Preparing Process Flow Chart ........................................................................31
2.12.2 Guidance for Material and Energy Balance .......................................................................31
2.12.3 Steps in Mass and Energy Balance Calculation .................................................................32
2.13 Ecological Economics .............................................................................................................................35
2.14 Energy Economics ...................................................................................................................................36
2.14.1 Embodied Energy Methodologies .......................................................................................37
2.14.2 Embodied Energy in Common Materials ..........................................................................37
References .............................................................................................................................................................38
Bibliography .........................................................................................................................................................39
3 Economics of Sustainable Engineering 41
3.1 Introduction .............................................................................................................................................41
3.2 Total Revenue, Total Costs, and Profit Relations ................................................................................41
3.2.1 Total Cost Function ...............................................................................................................41
3.2.2 Total Revenue Function ........................................................................................................41
3.2.3 Total Profit Analysis ..............................................................................................................42
3.3 Life Cycle Cost Analysis .........................................................................................................................43
3.4 Efficiency and Life Cycle Cost Calculation of a Pump .......................................................................44
3.4.1 Beyond Purchase Price ..........................................................................................................44
3.4.1.1 Calculating Total Life Cycle Cost ....................................................................45
3.4.2 Reduced Energy Costs ...........................................................................................................45
3.4.3 System Changes ......................................................................................................................45
3.4.4 Energy Savings through Pump Control .............................................................................46
3.4.5 Maximize Pump Efficiency ..................................................................................................46
3.4.6 LCC Educated Pump User ....................................................................................................47
3.5 Mechanics of Time Value of Money .....................................................................................................47
3.5.1 Relationships for Discrete Compounding ..........................................................................47
3.5.2 Geometric Gradient: Constant Percentage Increment .....................................................48
3.5.3 Nominal and Effective Interest Rate ...................................................................................51
3.6 Economic Project Selection ....................................................................................................................52
3.7 Benefit–Cost Relation for Recycling .....................................................................................................54
3.8 Selection of Renewable Energy over a Time Period ...........................................................................56
3.9 Cost-Estimating Technique ....................................................................................................................56
3.10 Estimating Techniques............................................................................................................................58
3.10.1 Sources of Estimating Data...................................................................................................58
3.11 Indexes .......................................................................................................................................................58
3.12 Parametric Cost Estimating ...................................................................................................................60
3.12.1 Power-Sizing Technique ........................................................................................................60
3.12.2 Learning Curve Method .......................................................................................................61
vi Contents
3.13 Developing a Cost-Estimating Relationship (CER) ............................................................................64
3.14 Sustainability Considerations in Cost Accounting ............................................................................65
3.15 Carbon Dioxide Sequestration and Storage.........................................................................................66
3.16 Sustainable Economy Problems.............................................................................................................68
References .............................................................................................................................................................72
Bibliography .........................................................................................................................................................72
4 Analytical Techniques for Sustainability Analysis 73
4.1 Nonlinear Optimization .........................................................................................................................73
4.1.1 Introduction to Optimization and Green Optimal Design .............................................73
4.1.2 Optimization Problem and Model Formulation ...............................................................74
4.1.2.1 Basic Components of an Optimization Problem ..........................................74
4.1.3 Objective Function .................................................................................................................74
4.1.4 Statement of an Optimization Problem ..............................................................................74
4.1.5 Basic Mathematical Model ...................................................................................................75
4.1.6 Requirements for Application of Optimization Methods to Optimal Design .............75
4.1.7 Basic Design Problem ............................................................................................................75
4.1.8 Optimal Design ......................................................................................................................76
4.1.9 Selection of Optimal Shape...................................................................................................77
4.1.9.1 Circular Tray Design .........................................................................................78
4.1.10 Issues to Be Resolved by the Algorithm Developer ..........................................................79
4.1.10.1 Gradient-Free Algorithms ................................................................................79
4.1.10.2 Diagnosis of Function Generator Difficulties (Knowledge-Based
Optimization) .....................................................................................................79
4.1.10.3 Robust, Sturdy Software ....................................................................................80
4.1.10.4 Noise-Tolerant Algorithms ...............................................................................80
4.1.10.5 Application-Oriented Software Design ..........................................................80
4.2 Single and Multiobjective Optimization: A Brief Overview .............................................................80
4.2.1 Model Development ...............................................................................................................82
4.2.2 Model Validation and Evaluation ........................................................................................82
4.2.3 Modeling Techniques ............................................................................................................82
4.2.3.1 Optimization Methods: Introduction and Basic Concepts .........................82
4.2.4 Variables ..................................................................................................................................82
4.2.5 Constraints ..............................................................................................................................82
4.2.6 Constraint Surfaces ................................................................................................................83
4.2.7 Formulation of Design Problems as Mathematical Programming Problems ..............83
4.2.8 Problem Formulation ............................................................................................................84
4.2.9 Selection of Design Variables ...............................................................................................84
4.2.10 Selection of Constraints ........................................................................................................84
4.2.11 Objectives ................................................................................................................................84
4.2.12 Models ......................................................................................................................................84
4.2.13 Representation in Standard Form .......................................................................................85
4.2.14 Problem Solution ....................................................................................................................85
4.3 Function of a Single Variable in Optimal Engineering Design ........................................................86
4.3.1 Monotonic Function ..............................................................................................................86
4.3.1.1 Unimodal Function ...........................................................................................86
4.3.1.2 Optimality Criteria ............................................................................................87
4.3.1.3 Inflexion Point or Saddle Point ........................................................................87
4.3.2 Concept of Global Optimum ................................................................................................89
4.3.2.1 Algorithm ............................................................................................................89
4.3.3 Region-Elimination Methods ...............................................................................................89
4.3.4 Global Optimum ....................................................................................................................89
4.3.5 Interval Refinement Phase ....................................................................................................91
4.3.6 Methods Requiring Derivatives ...........................................................................................94
4.3.7 Newton–Raphson Method ....................................................................................................94
4.3.8 Newton Second-Order Method ...........................................................................................95
Contents vii
4.3.9 Constrained Optimization ...................................................................................................95
4.3.10 Equality-Constrained Optimization ...................................................................................96
4.3.11 Lagrange Multiplier Method ................................................................................................96
4.3.12 Kuhn–Tucker Conditions......................................................................................................97
4.4 Engineering Design (Optimal Design) Examples ............................................................................102
4.5 Geometric Programming .....................................................................................................................116
4.5.1 Geometric Programming Model .......................................................................................116
4.5.1.1 Examples for Geometric Programming Problems .....................................117
4.6 Comparing Classical and Advanced Techniques for Optimization ..............................................136
4.6.1 Classical Optimization Techniques ...................................................................................136
4.6.2 Advanced Optimization Techniques ................................................................................136
4.6.3 Optimization Software ........................................................................................................137
References ...........................................................................................................................................................137
Bibliography .......................................................................................................................................................138
Section II Green Design and EOL Treatment
5 Principles of Green Design 141
5.1 Design for the Environment ................................................................................................................142
5.2 Environmentally Conscious Production............................................................................................144
5.3 Green Design Tools ...............................................................................................................................144
5.3.1 Mass Balance Analysis ........................................................................................................144
5.3.2 Green Indices ........................................................................................................................145
5.3.3 Energy Content .....................................................................................................................145
5.3.4 Eco-Indicators ......................................................................................................................145
5.4 Footprint Indicators ..............................................................................................................................145
5.4.1 Design for Disassembly and Recycling Aids ....................................................................146
5.4.2 Recycling ...............................................................................................................................146
5.5 Factors in Material Selection for Environmentally Conscious Design .........................................147
5.6 Green Designing and Machining ........................................................................................................147
5.7 Steps in Eco-Material Selection for Mechanical Components .......................................................149
5.7.1 Selection of Material by Cost/Unit Volume Consideration ...........................................149
5.7.2 Merit Index Method .............................................................................................................154
5.7.3 Performance Index Method ................................................................................................155
5.8 Materials Properties Chart ...................................................................................................................156
References ...........................................................................................................................................................162
Bibliography .......................................................................................................................................................162
6 End-of-Life Treatment and Environmental Impact Scenario 163
6.1 LCA Analysis at EOL ............................................................................................................................164
6.2 Minimization of Embodied Energy ....................................................................................................167
6.3 Minimization of Carbon Footprint ....................................................................................................169
6.4 Product’s GHG Flow .............................................................................................................................170
6.5 Low-Carbon Design ..............................................................................................................................170
6.6 Estimation of GHG Emission of a Product ........................................................................................171
6.6.1 Raw Materials Stage .............................................................................................................171
6.6.2 Manufacturing Stage ...........................................................................................................171
6.6.3 Distribution Stage ................................................................................................................172
6.6.4 Use Stage ................................................................................................................................172
6.7 End-of-Life Scenario .............................................................................................................................172
6.7.1 Estimation of Embedded GHG Emission of a Part .........................................................172
6.7.2 Concept of Low-Carbon Product System .........................................................................174
6.7.3 Establishment of GHG Emission Target ...........................................................................174
6.7.4 Establishment of BOM Structure ......................................................................................175
viii Contents
