building in sustainability - professor graham hillier
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Copyright CPI 2011. All rights reserved
Building in Sustainability
Prof Graham Hillier, CEng, FRSADirector of Strategy and Futures, CPI
Salford University
27th April 2011
• A bit about me
• A bit about the Centre for Process Innovation
• Why sustainable engineering is important
• Engineering for Sustainability Requires a Behaviour Change
• Examples of Sustainable Engineering
• Making the Change
Content
A Bit About Me
• Sponsored undergraduate at Rolls-Royce
• Metallurgy degree at Sheffield University
• PhD on single crystal turbine blades at Cambridge University
• Joined ICI worked in Polymer Films, Advanced Materials, Petrochemicals, Plastics and Fertilizers. Finished as Strategy Director
• Moved to British Steel/Corus in Business Development, Merger integration
• Became Corus Construction Director
• Joined CPI in Low Carbon Technologies – Included sustainable communities
• Now CPI Strategy and Futures Director
A Bit About Me
A Bit About CPI
Vision
• A World Class Innovation Centre supporting the Process Industries
CPI Moves to this Vision by:
• Build Physical Assets that bring together Companies, Universities, Public Sector Funds and Technology Expertise to develop new products and processes for the Process Industries
CPI’s Vision
Process Development, Proving and Scale Up
Innovation: Technology Readiness Levels (NASA)
TRL 1
TRL 2
TRL 3
TRL 4
TRL 5
TRL 6
TRL 7
TRL 8
TRL 9
Basic Technology Research
Research to Prove Feasibility
Technology Development
Technology Demonstration
System/Sub-System Development
System Test, Launch and Operation
RESEARCH(Universities)
TECHNOLOGY DEVELOPMENT(CPI)
BUSINESS DEVELOPMENT (Enterprise)
ECONOMICSUPPORT
CPI Works at Technology Readiness Level 4 Up
CPI Technology Development
• Organic Displays
– Rigid and Flexible
• Solid State Lighting
• Organic PV
• Electronic Packaging
• Barrier Films
– LCDs
– Organic PV
– Fuel Cells
• Materials
– Printable electronic formulations
Sustainable Processing Printable Electronics
• Process and product development
• Bio transformation reactions
– Anaerobic digestion
– Fermentation
– Photosynthesis
– Bio catalysis
– Marine processing
• Particulate Processing
– Dispersion
– Crystallisation
– Emulsions and blending
• Sustainable Systems
– Engineering
– Communities
Located at Wilton Centre
Semi technical area- pilot manufacture
Modern laboratoryspace
Office accommodation
World classanalytical facilities
Land & infrastructurefor manufacturing
32 companies on site
Some of the CPI Assets
National Industrial Biotechnology Facility
Process Intensification
Bioprocess Lab
Marine Fermentation
SEM
Clean Room
Mask writerLitho area
Some of the CPI Assets
The Sustainability Challenge
Sustainable Development is development that meets the needs of the
present without compromising the ability of future generations to meet
their own needs […]. In essence Sustainable Development is a
process of change in which exploitation of resources, the direction of
investments, the orientation of technological development and
institutional change are all in harmony and enhance current and future
potential to meet human needs and aspirations.
(WCED, Brundtland Commission ,1987)
The Definition of Sustainability
Engineering and Built Environment Have Much to Contribute
The Principles of Sustainability
Create a balance between:
• Economic Factors
– Creating wealth to do things and continue to do them
• Environmental and Natural Resource Factors
– The impact on the resources we have available
• Societal Factors
– That we have healthy, happy full lives
The Three Factors are Equally Important
The Challenge of Sustainability
Dealing with:
• Growing Population
– Inexorably increasing the need for food and shelter
• Growing Affluence
– The amount of emissions rise with affluence and we use more
• Resource Consumption
– There is only a finite resource it will not last for ever
This Puts Immense Stress on a Finite System
WHY SUSTAINABLE ENGINEERING IS IMPORTANT?
Life Expectancy
Doubled in 150 Years in Developed WorldDeveloping World will follow
Life ExpectancyMassachusetts, US Historical Statistics
35
40
45
50
55
60
65
70
75
80
85
1850 1860 1870 1880 1890 1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000
Lif
e E
xp
ec
tan
cy
in
Ye
ars
Carbon Dioxide in the Atmosphere Rises with Population
Carbon Dioxide Concentrations Year on Year(Mauna Loa Observatory, Hawaii)
250
270
290
310
330
350
370
390
1830 1880 1930 1980
Atm
osp
heri
c C
arb
on
Dio
xid
e (
pp
mv)
0
1000
2000
3000
4000
5000
6000
7000
Po
pu
lati
on
(M
illi
on
s)
Carbon Dioxide Emissions (ppmv) Population
Source: Mauna Loa Observatory plus historic data from ice cores
Food Prices are rising
European Wheat Price Year on Year
0
20
40
60
80
100
120
140
160
180
200
1259 1359 1459 1559 1659 1759 1859 1959
WH
EA
T P
RIC
E I
N $
/tonne
0
1000
2000
3000
4000
5000
6000
7000
Popula
tion in M
illio
ns
Actual 179 pt Moving Average 49pt Moving Average Population
Carbon Dioxide Emissions Rise with GDP but….
There seems to be a levelling out at 7.5 t/yr to 10 t/yr
Carbon Dioxide Emissions per Person v GDP per Person By Country
Sw itzerlandSw edenIceland
FranceBelgium
Norw ay
Austria
Hong Kong
Republic of Ireland
Cameroon
ItalyUnited KingdomJapanNetherlands
European Union
Luxembourg
Spain
Germany
TanzaniaCosta Rica
Finland
Uruguay
New Zealand
Angola
Portugal
SudanPeruEl SalvadorGuatemala
Cyprus
Latvia
KenyaBrazil
Panama
Slovenia
Sri Lanka
Canada
United States
Singapore
Australia
Colombia
LithuaniaMexico
Israel
World
Bangladesh
Chile
Nigeria
CroatiaTurkey
South Korea
TunisiaGhana
ArgentinaEcuador
Lebanon
Slovakia
PhilippinesMoroccoYemen
Venezuela
Czech Republic
United Arab Emirates
Algeria
Poland
Kuw ait
Dominican RepublicPhilippinesMoroccoYemen
Venezuela
Czech Republic
United Arab Emirates
Algeria
Poland
Kuw ait
Dominican RepublicZimbabw eIndonesia
Romania
Qatar
Malaysia
Saudi ArabiaOman
Pakistan
Estonia
ThailandJordan
Vietnam
South AfricaLibya
Egypt
Bulgaria
India
Serbia and Montenegro
Bahrain
DenmarkGreece
Hungary
0
5
10
15
20
25
30
35
40
45
50
0 10 20 30 40 50 60 70 80
GDP per Person ('000 US Dollars 2005)
Carb
on
Dio
xd
ie E
mis
sio
n p
er
Pers
on
(t
/year)
Oil?
Air Conditioning?
Source data: US Statistics Service and UK
Population Growth Alone Will Increase Atmospheric Carbon Dioxide Concentration Significantly
Dealing with this Much Carbon Dioxide is a Challenge
43.5 (180%)67.57.59Rich World 2050 Population
9 (38%)333.69Base Case 2050 Population
26 (108%)507.56.6Rich World 2005 Population
243.66.6Base Case 2005
Increase over 2005 Base
Case (bn t/yr)
Total Annual Human CO2
Emissions(bn t / yr)
Average CO2
Emissions per Person (t/yr)
Population (billion)
Case
Earth
Incoming Energy
Resources Used
Earth Resource Balance Since 1850
Resource Use exceeds Incoming Energy
Extract Resource
Refine Resource
Use Resource
Scrap Resource
Waste
Air Emission
Water Emission
Resource Availability
Many Important Elements Our ‘Renewable’ Technologies Need Are in Short Supply
35%57-90 YearsNickel
43%36-45 YearsGold
26%36-46 YearsZinc
0%19-59 YearsUranium
17-40 Years
13-30 Years
8-42 Years
9-29 Years
4-13 Years
Available Resource
26%Tin
-Antimony
72%Lead
16%Silver
0%Indium
Recycling RateElement
Source: New Scientist, May 2007, Chemistry World Jan 2011
• Neodymium, Dysprosium, Terbium – Vital to high power magnets• Lithium, Lanthanum – Vital to high power batteries• 93% of world rare earth metals come from China • Availability is falling because regional use is rising!
There is a Strong Belief that Oil Production is Peaking
It is Highly Likely That Oil Production Will Peak in the Near Future
Source: Hubbert Model From Association for the Study of Peak Oil, 2008
Resource Demand in A Simple Equation
We Need to Become More Efficient in Our Use of ResourcesAn 80% Reduction comes from Increased Efficiency or Less Activity
CO2 Emissions = Population x Gross Domestic Product x Energy Used x CO2 EmissionPopulation GDP Energy Used
Waste = Population x Gross Domestic Product x Resource Used x Waste Made Population GDP Resource Used
Based on work by Shell scenario planning group
So What Do We Have to Do..
• Develop more sustainable processes
• Use resources more efficiency
• Improve the efficiency of our processes
• Look at the efficiency of integrated systems
• Convert wastes to products
• Convert batch processes to continuous ones
Top Six are Increasingly Strong Political and Economic Drivers
Bottom Two are Our Areas of StrengthThere is a Lot We Can Do
ENGINEERING FOR SUSTAINABILITY REQUIRES A
BEHAVIOUR CHANGE
Approaches to Improved Energy Efficiency, Resource Efficiency and Carbon Reduction
Significant Improvements can be Made
Reduce use of resources
Make sure operational resource use is as low as possible
Use highly efficient conversion technologies
Add on additional technologies
Reduces • Resources Consumed• Cost• Emissions• Wastes
Increases• Efficiency of Resource Use
Requires• A Different Way of Thinking• Less Conventional Technology
Sustainability in Practice: A Schematic Model
Raw Material Component End of LifeSystem
Recycle Recondition Re-furbishRe-use
AssembledProduct
Resource Efficient Flexible & Adaptable Design
EXAMPLES OF SUSTAINABLE ENGINEERING AND
CONSTRUCTION
Plastic Film Production
20% Operational Improvement Gives 75% Value Increase
Produce New Polymer
Convert toFilm
PrimeProduct
EdgeTrims
FailedProduct
CustomerRecycle Waste
5
(10)
(10)
100
(20)
Value, £/t
60% Prime40% PrimeStage
6
54
50
10
40
46
Tonnes
10
90
50
10
40
% Pass
Value, £Tonnes%
Pass
Value, £
100t Capacity
Total Value
Waste
Recycle
Failed
Product
Edge Trim
Prime Product
New Polymer
42802470
2041030
(360)3690(540)
3030
(100)1010(100)
600060604000
(1280)64(920)
Baffle Reactor
Lower Capital and Operating Cost. Less Resource use and Less Waste
Batch to Continuous
• Lower inventory
• Make what you need
• Plug flow so easy to clean
• Highly efficient mixing
• Capital down up to 50%
• Operating cost down up to 90%
Pump Impeller
Greater Efficiency in Use, Less Resource and Lower Cost
Steel to Plastic• Lower capital cost• Less material• More hydrodynamic efficiency• Smaller motor or higher volume pumped• Quieter in use
The Steel Mini-Mill
• Completely changed the complexion of the steel industry
• Uses locally arising scrap to supply a local market
• Capital reduced by an order of magnitude, operating costs are low
• Much lower logistics costs
• Batches can be smaller
• Investment is affordable
• Product is the same quality as virgin steel for sections, rod and bar
• Now 30% (400 million tonnes / year) of steel production
• Changed by the small upstart company not the incumbents
• Overall system cost is lower
What Else Can we Change Like This?
Drivers in Construction
• Increasing emphasis on the through life cost
• Increasing regulatory requirement for improved energy performance and reduced waste
• PPP type contracts are for service delivery over time not capital cost
• Drive the need for:
– Rapid build with good quality finishes
– Safety, cleanliness, low disturbance and low waste
– Flexible and adaptable buildings
– Low through life energy use
– Low end of life costs
An Opportunity for Change that we are Resisting
Energy Life Cycle for Offices
Extraction Manufacture
Construction
Use (and Refurbishment) Demolition
Disposal, including Re-use and Recycling
Building Energy Consumption is Higher in Use than in Manufacture and Construction
Source: Amato PhD 1995
FOR SALFORD(Temperate)
• Solar heating
• Natural Ventilation
• Artificial Heating
• Free Heating
• Insulation
• Daylight
Reference: Architecture and the Environment Bioclimatic Building Design, David Lloyd Jones, 1998
Housing Concepts
Source: Grimshaw and Partners for World Steel Organisation
Building Sustainable Features into New Buildings
• Engineering design that uses the principles
– Build sustainability in
• Plan the assembly before manufacture and erection
– E.g. Distribution sheds
• Use of off-site manufacture or pre-assembly of components
– Walls, Floors, Roofs
• Use of IT in design manufacture and assembly
– Basic design, Fluid dynamics, Virtual reality simulation
Following Virtual Example Brings Together Existing Technology from Around the World
Sustainable Features in Buildings
Source: Grimshaw and Partners for International Iron and Steel Institute, 2004
Refurbishment and Reuse Opportunities
• Half the value of the European construction market is refurbishment
• Buildings made from components or framed in steel lend themselves to reuse
– Reuse whole frame
– Extend or refashion existing building
– Dismantle and reuse component parts
• Improve structure, e.g.
– Insulate
– Overclad
– Glazing
• Micro generation, e.g.
– Solar, wind
– Anaerobic digestion
– Grey water
Refurbishment and Reuse Example: Winterton House
Source: Corus, Late 1980s
Social Factors
• Related to lifestyle and perception
• Difficult to gain objective measures
• Make people feel good about their environment
• Elements such as:
– Physical appearance
– Function, form and operation
– Balance and quality of public and private spaces
– Ergonomics
– Security and safety
– Transport
Environmental Impact: Examples of Sustainable Construction
Environmental Impact in Construction
1 2 3 4
5 6 7 8
Ashden Rwandan Prison Anaerobic Digestion Example
True Sustainable Intervention: Eliminate 2 problems, Create solutions and Educate people to use their skills to repeat the benefit
• Influx of people to a resource poor community,
• Burns all the fire wood, generates untreated sewage,
• Prisoners built anaerobic digestion plant in the gardens
– Exclude air from pit of sewage and natural bacteria produce methane
• No need to denude fire wood
• No sewage problem
• By-product is digestate for use a fertilizer
Source: Ashden Awards, AD Section
Resource Efficient Systems Integrate Technologies to Reduce Consumption
Community, Town, Factory,
Store,Home
ExcessHeat
IC ENGINE
FUEL CELL
GAS TOP UP
INCINERATE
GASIFY
DIGEST
FERTILIZER, COMPOST WASTE GLASS & METAL
COOLING
ELECTRICITY
HEAT
CLEAN
GAS
GRID TOP UP WIND TURBINE
EXTRA WASTESORT
Waste
VEHICLEFUEL
MAKING THE CHANGE SO A SUSTAINABLE BUILT ENVIRONMENT
BECOMES PART OF OUR FUTURE
Big Challenges to Adopting Sustainable Principles
• Global drivers and trends in resource availability favour this approach but we must:
– Look at engineering and built environment problems differently;
– Make sure policy makers, business leaders, engineers and construction industry understand change is needed and is possible;
– Aspire to deliver the benefits;
– Work collaboratively across technical and social disciplinary boundaries;
– Create a favourable legislative and regulatory environment
– Take account of the value of finite resources in our economics;
– Make attractive, reliable and useable products and demonstrate there are benefits.
There is a Large Opportunity for Economic, Social and Environmental Benefit
We need to Change Our Behaviour and Do Something
What Could We do?
To do this we need to:
• Facilitate links between research, development and commercial interests to create value through application development.
• Create a range of supply partnerships appropriate to end users to increase adoption.
• Build supply chain networks that develop the UK industry base.
• Utilise a range of funding sources.
Create a ‘Low Carbon Resource Efficient Community’
Based on an integrated set of projects
that
Combine industrial, residential, agricultural and transport applications
to
Exploit the inherent strengths of the Communities and Regions
And
Deliver Economic Well Being
An Case Study of an Innovation Challenge
LightFossil Carbon
Fossil Fuel Gas Production Unit
Anaerobic Digestion Unit
Bio Processing
Power Generation
Land
Heat Production
Oils
Food
Pharmaceuticals
Neutraceuticals
Alkane, Alkene
or Alkyne
Hydrogen
Extra
ctio
n
Rapid Plant Growth
Carbon Dioxide
Plant Matter
Depleted PlantMatter
Fertilizer
Hydrogen
Oxygen
Carbon Dioxide
And Nutrients
Food Waste
Sewage
Brewing ands Distillery Waste
Bio Diesel and Bio Ethanol Waste
Vehicles
Source: Entering the Ecological Age: The Engineer’s RoleCPI and Arup
Water
Methane
Conclusions
• Design things that use little energy
• Make or build them as efficiently as possible, preferably with reuse in mind
• Think about resource flows before you design
• Think about resource flows through communities and systems
• Think how wastes can be eliminated or used as fuels or feedstocks
• Drive collaborative interdisciplinary working
• Take action
REDUCE, REUSE, RECYCLE, RELATE
Copyright CPI 2011. All rights reserved
The Centre for Process Innovation
www.uk-cpi.com
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