environmentally conscious design & manufacturing (me592) date: march 24, 2000 slide:1...

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:1

Environmentally Conscious Design & Manufacturing

Class 9: Health & Environmental Issues

Prof. S. M. Pandit

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:21

Health and Environmental Issues

Cutting fluids in manufacturing EPA water quality monitoring Analytical monitoring tools Health hazards Where does it fit?

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:32

Additives: Chlorine, Sulfur, Phosphorus, Biocides, Odorants

C u ttin g F lu id s

S tra ig h t O ils E m u ls ion s

O il B ased

S yn th e tic s S em i-syn th e tic

C h em ica l

Cutting Fluids in Machining

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:4

Claimed Benefits of Cutting Fluids

•Lubrication•Heat transfer•Chip flushing______________________________________•Increased tool life•Reduced thermal deformation•Improved surface finish•Reduced forces•Corrosion protection of surface•Workpiece cleaner

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:5

Cutting Fluid Liabilities - 1

• Fluid disposal due to contaminant build-

up

• Fluid performance is time dependent

• Maintenance, disposal, handling,

protection,

and acquisition expensive

• Hazardous chemical constituents

• Source of occupational airway disease

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:6

Cutting Fluid Liabilities - 2

• Source of contact dermatitis

• Excessive BOD, FOG, Nitrogen, Phosphates

• Expensive pre-treatment prior to disposal

(wastewater currently sent to POTW - changes

to permissible level of contamination being

considered - may require additional expensive

pretreatment)

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:7

Cutting Fluid Types(Straight Oils / Soluble Oils)

• Straight oils - Non-emulsifiable. Base oil, and often fats, veg. oil, & esters. May include extreme pressure additives such as Chlorine, Sulphur, Phosphorus.

• Soluble oils - Form emulsion when mixed with water. Typical concentrations of 3-10% - least expensive.

• Synthetic fluids - Formed from alkaline inorganic & organic comp. + corrosion inhibitors. Diluted form.

• Semisynthetic fluids - Combo. of synthetic & sol. oil.

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:8

Straight Oil EP Additives

Some suggest that EP additives react with work material - form a barrier film that provides lubrication

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:9

Straight Oils: Pros and Cons

Pros Cons

Good lubrication Expensive - hard materials

Rancidity & degradation Flammable resistant

Good rust protection Smoke prone

Low maintenance Health hazard

Lack of cooling

Viscosity low

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:10

Straight Oils vs. Water Solubles

Straight Oils Water Solubles

Degradation resistant High thermal conductivityGood lubrication Good cooling abilityEasier to recycle More economicalGood surface wettability Better operator acceptanceGood rust protection No fire hazard Less oil misting

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:11

Cutting Fluids in Machining(reducing waste)

Waste Reduction and Recycling Methods

- Use water-soluble metal working fluids.- Use de-mineralized water make-up- Perform regularly scheduled sump and machine cleaning.

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:12

ArsenicAsbestosBariumChromiumCyanideMercuryNickelNitrateSeleniumLeadCopper

Inorganics

pH Alkalinity

• Testing water

Question:

What is happeningto groundwater,lakes and rivers?

EPA Water Quality Monitoring -1

(see epa.gov for complete list)

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:13

BenzeneCarbon Tetra ChlorideChloroethyleneStyreneTolueneTrichloromethanes

Organics

EPA Water Quality Monitoring - 2

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:14

Analytical Monitoring Tools

AtomicAbsorption

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:15

Mass Spectrometry

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:16

Mass Spec

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:17

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:18

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:19

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:20

Manufacturing

Liquid wastes (cutting fluids) Testing of effluents

Source reduction

Waste treatment Recycle / Reuse

Where Does It Fit?

Environmentally Conscious Design & Manufacturing (ME592)

Date: March 24, 2000 Slide:21

Homework #3The following problems are out of the textbook “Industrial Ecology”

1. Problem 8.1

2. Problem 8.2

3. Problem 9.3

Hint: A simple and reasonable technique is to sum the row entries and

column entries. An overall rating is given by adding row totals(or the

equivalent, column totals) so that the entire matrix is summed.

Answer: Design 2 is better than design 1 because design 2 has higher

overall score (48 to 43), and the product use rating, and many products

have their greatest impact during the in-use stage.