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

CPI receives funding from: