GREEN BY DESIGN
Pratt & Whitney’s Green Engine Program
Columbia University
Industrial Ecology Course
February, 2001
Pratt & Whitney - United Technologies Corporation
Pratt & Whitney
Bob Tierney
Today’s topics...
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United Technologies Corporation
Pratt & Whitney’s Green Engine Program
Our conception of Life Cycle Assessment
Elimination of hazardous materials from life
cycle
• Strategic thoughts on implementing green
Progress !!
Lead air emissions
98% decrease
1970-95
Lead in child’s blood
82% decrease
1976-95
CO emissions
30% decrease
1970-92
Auto hydrocarbons
98% decrease
1970-95
Lakes/ rivers
60% fully meet water stds.
Bald eagle
off endangered species list
Sewage
100% treated in US (EU -72%)
U.S. data unless noted
Progress ??
Electricity use per capita
21 % increase
Aluminum consumption
1200% increase 1970-88
CO2 concentration
7% increase
1975-95
Waste to landfills
34% increase
1970-90
Ozone hole
60% deeper
1970-95
U.S. data unless noted
1977-87
The Master Equation
Global
Envi.
Impact
= Population X
Resource
use
Person
Unit of Waste
X Unit of Resource
Drivers for Green
•
•
•
•
•
•
•
State of the environment
Customers
Bottom line (Green = $$$$)
Top Line Growth
Wall St.
Politics/ Regulations
UTC Policy/ 10X Goals
Local Restrictions Increasing at an Accelerating Rate *
Noise Abatement
Procedures
Number of Restrictions
Curfews
400
350
300
250
200
150
100
50
0
1970
Charges
Levels
Quotas
Budgets
Ch. 2 Phase-out
Ch. 2 Restrictions
Ch. 3 Restrictions
1980
1990
2000
Year
* Based on 594 airports in Boeing database
2/22/00
http://www.boeing.com/assocproducts/noise/list.html
25
Green Engine Program is structured
as a matrix organization
Design
Suppliers
Management
Green Factory
Technology
Customer
Requirements/
Communications
Life Cycle Assessment: The Stages
For the sake of simplicity the life cycle is divided into unit processes usually broken down as follows: premanufacture, manufacture, distribution and installation, use and service, and end of life management. Each unit
process is then evaluated in three areas: safety, conservation, and pollution. The inputs and outputs of each life
stage are the criteria for evaluation.
Pre-Manu
facture
Manufacturing
Distribution
Use &
Service
Recovery
Management
Reuse
Remanufacture
Revert
CO2 Emissions
Factory vs. Use
MILLION METRIC
TONS OF CO2
120
100
80
60
40
20
0
55X
UTC
P&W FLEET
Develop Process Map with the
“Goes-Ins” and the “Goes-Outs”
Inputs
Outputs
Process or Activity
Product or
Service
Raw Materials Actions of People,
By-products
Equipment, Machines
Chemicals
Reactions of
Energy
Injuries
Chemicals
and
Materials
Fuels
Illnesses
Electricity
Inefficiencies
Air Emissions
Water Discharges
Solid/Liquid Waste
Tap Into Existing Data Sources
Degreasing
4%
Misc..
Sources
32%
Machining &
Metalworking
8%
Painting
14%
All Other Injuries
43%
Ergonomic
Injuries
57%
Plating
5%
Material Handling
37%
Stripping
9%
Cleaning &
Rinsing
11%
Surface Preparation &
Treatment
17%
Hazardous waste sent off
site by process source
Maintenance &
Service
11%
Manufacturing &
Assembly
26%
Injuries by type
and operation
Is it Good, Bad or Ugly?
EH&S IMPACTS
LIFE STAGE
PREMANUFACTURE
MANUFACTURE
DISTRIBUTION &
INSTALLATION
USE &
MAINTENANCE
END OF LIFE
MAKE PRODUCTS
& WORKPLACE
SAFE
PROTECT
ENVIRONMENT
CONSERVE
RESOURCES
Elements of a Green Engine
Vision: Pratt & Whitney sets the Standard for Green
Has the lowest possible
Emission Impact during use
Has lowest possible
Noise Impact
Is manufactured and
serviced using
Green Processes
Is designed with
Human Factors
in mind
Is Material Efficient
(Metal Buy-to-fly,
Propellant Yield )
Is Energy Efficient
during use
(Fuel Burn)
Contains
Green Materials
Has least possible
Factory Impacts
Involves Green Suppliers
and Partners
Is Designed for
Serviceability, Reusability, Recyclability
Understanding Impacts is Key to Continuous Improvement
Job Ticket/
SRD/ CRD
LCA
Goals
Design
Standard Work
Design
Specifications
Procurement
Process
Operating
Procedures
End of Life
Service
Use
Distribute
P&W
Manufacturing
Environment, Safety, Natural Resources Impact
Supplier
Manufacturing
Knowing Where to Apply the ‘Green’ Pressure Points
Technology
Team
Customer
Req’mt Team
Supplier
Team
Job Ticket/
SRD/ CRD
LCA
Goals
Design
Standard Work
Design
Team
End of Life
Design
Specifications
Operating
Procedures
Green Factory
Team
Service
Use
Procurement
Process
Distribute
P&W
Manufacturing
Environment, Safety, Natural Resources Impact
Supplier
Manufacturing
LCA as Part of Integrated
Program Deployment (IPD)
PRODUCT
LIFE CYCLE
ASSESSMENT
TECHNICAL SUPPORT
PLANNING
DEFINITION
VALIDATION
DELIVERY
Product
Requirements
Objectives
& Targets
EH&S ANNUAL PLANNING& EVALUATION
SUPPORT
Market
Feedback
Analysis
Aspects
&
Impacts
Baseline LCAs are the Standard by Which
Future Products Are Compared
Large Gas Turbine Engine
General Aviation Engine
Liquid Rocket (expendable & serviceable)
Solid Rocket (expendable & serviceable)
What is a Life Cycle Assessment?
•Qualitative process used to assess EH&S
impacts of product during its lifecycle
What does it provide?
•Relative magnitude of EH&S impacts
•Areas of information gaps
•Priorities for green design
•Priorities for green technology development
And….
•Raises consciousness of organization
Materials/ Processes of Concern
MATERIALS OF CONCERN FOR GAS TURBINE
AND ROCKET PROPULSION SYSTEMS
• Materials Of Concern
• Hazardous Materials Index
• Product Comparisons
• Standard Work
• Green Technology Goals
• Summary
Materials Of Concern
Objectives
• Identify hazardous material risks across the enterprise
• Provide a deliverable for incorporation into standard work
• Create a green index to drive green technology plan
Rationale
• Appearance of targeted materials on one or more industry,
customer or regulatory list(s) of hazardous materials
• Relevance to Pratt & Whitney product lines or processes
• Potential linkage to product and process design callouts
Definition Of Categories
• Prohibited
– high risk materials not permitted in new design and
development
• Restricted
– high risk materials that can only be used with
appropriate levels of approval
– plan must be established to validate alternate green
material
• To Be Reduced
– materials known to have detrimental environmental,
health and safety impacts.
Materials of Concern
Prohibited
Arsenic & compounds
Asbestos
Benzene
Beryllium
Cadmium & compounds
Chlorinated solvents
Ethyl alcohol
Ethylene glycol ether
compounds
Formaldehyde
Mercury & compounds
Methanol (methyl alcohol)
Methylene chloride
Class I ozone depleting
substances
Radioactive materials,
including
Thoriated (TD) nickel
Toluene diisocyanate
Restricted
Chromium, hexavalent
Class II ODS
Cyanides
Dimethylformamide
HCFC-14 lb & HCFC-22
Hydrazine
Hydrofluoric acid
Hydrogen fluoride gas
Lead & compounds
Manmade fibers, e.g.,
cristobalite, fiberfrax
MDA (4’, 4’-Methylenedianiline)
Methyl alcohol (methanol)
Methyl ethyl ketone (MEK, 2butanone)
Methyl iso-butyl ketone
(MIBK, 4-methyl-2-pentanone)
Phenol
Styrene
Toluene
Xylene
To Be Reduced
Acetone
Ammonia
Butyl alcohol
Ethyl benzene
n-Hexane
Hydrochloric acid
Isocyanates
n-methyl-2-pyrrolidone
Isopropyl alcohol
Nickel plate
Nitric acid
Petroleum distillates
(e.g.,
naptha, mineral spirits,
stoddard solvent,
varsol,
evaporative lubricants)
Phosphoric acid
Sec-butyl alcohol
Sulfuric acid
1, 2, 4Trimethylbenzene
Hazardous Materials Index
• Purpose
– provide metric to define “greenness” of products
– link materials to specifications/design callouts
• Assign “toxicity” values to materials & process
specifications based on Purdue University rankings
• Quantify green indices based on Pratt & Whitney
Canada algorithm:
Ih =
T*nP/N
where: Ih = Hazardous Material Index
T = toxicity value of specification
nP = number of part numbers that call out specification
N = total number of part numbers in engine
Hazardous Materials Index
Implementation
• Establish metrics/set goals
• Establish signoff/approval protocols
• Control via standard work
Restricted Materials of Concern - Current
Status of Various Engine Programs
Hazardous Materials Index
30
25
20
15
10
Technology
Opportunity
5
0
JT8D-219
PW2037
PW4168
Goal
Standard Work
Materials Of Concern
• Contains background, contacts and protocols
• References material and process specification list
• Links to data base containing materials of concern,
toxicity rating detail, identified by specifications
• Links to menu for selection of alternate materials and
processes, cross-referenced by specification
Materials of Concern List with
Specification Number
Specification Number
Hazardous Material
PWA-316
Lead
PWA-333
Xylene, Toluene
AMS-3110
Chromium, Toluene
QQ-P-416
Cadmium
PWA-315
None
PWA-1469-3
None
AMS-3242
None
Green Technology Goals
• Goals established based on driving down product
hazardous materials index
• Goal for legacy products will be based on
designing out prohibited materials
• Goal for new designs will be based on eliminating
the use of restricted materials
Summary
• Comprehensive effort to identify hazardous
material risks across the Pratt & Whitney
enterprise
• Risks defined by levels of concern
• Standard work tool for designers established
• Goals in process of being defined
• Hazardous Materials Index will drive technology
Rod Elkington, Chairman:
“Tomorrow’s economy will be about increasing
returns where we learn to exploit virtuous
cycles rather than manage vicious ones.”