GREEN BY DESIGNPratt & Whitney’s Green Engine Program

Columbia University

Industrial Ecology Course

February, 2001

Pratt & Whitney

Bob TierneyPratt & Whitney - United Technologies Corporation

Today’s topics...

• 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 1977-87

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

The Master Equation

GlobalEnvi.

Impact= Population Resource

use Person

Unit of WasteUnit of ResourceX X

Drivers for Green

• State of the environment

• Customers

• Bottom line (Green = $$$$)

• Top Line Growth

• Wall St.

• Politics/ Regulations

• UTC Policy/ 10X Goals

* Based on 594 airports in Boeing database

050

100150200

250300

350400

1970 1980 1990 2000

Year

Noise AbatementProcedures

Curfews

Charges

Levels

Quotas

Budgets

Ch. 2 Phase-out

Ch. 2 Restrictions

Ch. 3 Restrictions

Nu

mb

er o

f R

estr

icti

on

s

Local Restrictions Increasing at an Accelerating Rate *

2/22/00http://www.boeing.com/assocproducts/noise/list.html

25

Green Engine Program is structured as a matrix organization

Management

Green Factory Technology

Design

Customer Requirements/

Communications

Suppliers

Life Cycle Assessment: The StagesFor the sake of simplicity the life cycle is divided into unit processes usually broken down as follows: pre-manufacture, 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-Manufacture

Manu-facturing

Revert

Reuse

Use &Service

RecoveryManagement

Distribution

Remanufacture

CO2 Emissions

0

20

40

60

80

100

120

MIL

LIO

N M

ETR

IC

TO

NS

OF C

O2

UTC

P&W FLEET

Factory vs. Use

55X

Develop Process Map with the “Goes-Ins” and the “Goes-Outs”

Inputs Outputs

Process or Activity

Product or Service

Raw MaterialsChemicalsEnergyFuelsElectricity

Actions of People, Equipment, MachinesReactions of Chemicals and Materials Injuries

IllnessesInefficienciesAir EmissionsWater DischargesSolid/Liquid Waste

By-products

Tap Into Existing Data Sources

Plating 5%

Stripping 9%

Painting 14%

Machining & Metalworking

8%

Degreasing 4%

Misc.. Sources

32%

Cleaning & Rinsing

11%

Surface Preparation & Treatment

17%

Hazardous waste sent off site by process source

Hazardous waste sent off site by process source

Ergonomic Injuries

57%

All Other Injuries43%

Maintenance & Service

11%

Manufacturing & Assembly

26%

Material Handling37%

Injuries by type and operation

Injuries by type and operation

Is it Good, Bad or Ugly?

EH&S IMPACTSLIFE STAGE MAKE PRODUCTS

& WORKPLACESAFE

PROTECTENVIRONMENT

CONSERVERESOURCES

PREMANUFACTURE

MANUFACTURE

DISTRIBUTION &INSTALLATIONUSE &MAINTENANCEEND OF LIFE

Has lowest possibleNoise Impact

Has the lowest possible Emission Impact during use

Contains Green Materials

Is designed with Human Factors

in mind

Has least possible Factory Impacts

Is Material Efficient (Metal Buy-to-fly,Propellant Yield )

Is manufactured andserviced usingGreen Processes

Involves Green Suppliers and Partners

Is Designed for Serviceability, Reusability, Recyclability

Is Energy Efficient during use (Fuel Burn)

Elements of a Green EngineVision: Pratt & Whitney sets the Standard for Green

LCA

Distribute

DesignSpecifications

SupplierManufacturing

ProcurementProcess

OperatingProcedures

P&WManufacturing

Goals

Job Ticket/SRD/ CRD

DesignStandard Work

UseServiceEnd of Life

Environment, Safety, Natural Resources Impact

Understanding Impacts is Key to Continuous Improvement

LCA

Distribute

DesignSpecifications

SupplierManufacturing

ProcurementProcess

OperatingProcedures

P&WManufacturing

Goals

Job Ticket/SRD/ CRD

DesignStandard Work

UseServiceEnd of Life

Environment, Safety, Natural Resources Impact

Green FactoryTeam

TechnologyTeam

DesignTeam

Customer Req’mt Team

SupplierTeam

Knowing Where to Apply the ‘Green’ Pressure Points

LCA as Part of Integrated Program Deployment (IPD)

Aspects & Impacts

Objectives & Targets

EH&S ANNUAL PLANNING& EVALUATIONEH&S ANNUAL PLANNING& EVALUATION

PRODUCT LIFE CYCLE ASSESSMENT

PLANNING DEFINITION VALIDATION DELIVERY SUPPORT

Product Requirements

Market Feedback Analysis

TECHNICAL SUPPORT

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 ConcernObjectives

• 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

Arsenic & compoundsAsbestosBenzeneBerylliumCadmium & compoundsChlorinated solventsEthyl alcoholEthylene glycol ether compoundsFormaldehydeMercury & compoundsMethanol (methyl alcohol)Methylene chlorideClass I ozone depleting substancesRadioactive materials, including Thoriated (TD) nickelToluene diisocyanate

Chromium, hexavalentClass II ODSCyanides DimethylformamideHCFC-14 lb & HCFC-22HydrazineHydrofluoric acidHydrogen fluoride gasLead & compoundsManmade fibers, e.g., cristobalite, fiberfraxMDA (4’, 4’-Methylenedianiline)Methyl alcohol (methanol)Methyl ethyl ketone (MEK, 2-butanone)Methyl iso-butyl ketone (MIBK, 4-methyl-2-pentanone)PhenolStyreneTolueneXylene

AcetoneAmmoniaButyl alcoholEthyl benzenen-HexaneHydrochloric acidIsocyanatesn-methyl-2-pyrrolidoneIsopropyl alcoholNickel plateNitric acidPetroleum distillates (e.g., naptha, mineral spirits, stoddard solvent, varsol, evaporative lubricants)Phosphoric acidSec-butyl alcoholSulfuric acid1, 2, 4-Trimethylbenzene

Prohibited Restricted To Be Reduced

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

0

5

10

15

20

25

30

JT8D-219 PW2037 PW4168 Goal

Ha

zard

ou

s M

ate

ria

ls In

de

x

Technology Opportunity

Standard WorkMaterials 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.”