Ecodesign by J Lery (Dassault)

Round TableEco-Design & LCA in aeronautics

Le Bourget, June 20th, 2011

LifeCycle Assessment of Materials and Processes

J. Lery – Dassault Aviation

This document is the property of one or more Parties to the Clean Sky Eco-Design ITD consortium and shall not be distributed or reproduced without their formal approval

Clean Sky Objectives – Eco-Design ITD

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GENERAL ACARE OBJECTIVES• 80% cut in NOx emissions• Halving perceived aircraft noise• 50% cut in CO2 emissions per pass-Km by drastic fuel consumption reduction• A green design, manufacturing, maintenance and disposal product life cycle

• 80% cut in NOx emissions• Halving perceived aircraft noise• 50% cut in CO2 emissions per pass-Km by drastic fuel consumption reduction• A green design, manufacturing, maintenance and disposal product life cycle

ECO-DESIGN ITD(Airframe part)


• Development of A/C technologies to reduce environmental impacts during out-of-operation phases of the A/C lifecycle

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Eco-Design for Airframe (EDA) Objectives

Reduction of inputs and outputs

Reduction of inputs and outputs

Technology areas along the lifecycle

Technology areas along the lifecycle


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TECHNOLOGYSoA

ScopingSelection for development

Selection for demonstration

Development maturation

DEMONSTRATIONDemo. Def.

Demonstration

Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7

2009 2010 2011 2012 2013 2014

SYSTEMReqts

Eco-Statement - LCA Final Eco-St. - LCA

Guidelines

Evaluation tools - LCA to TE

EDA Overall Logic


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State of the art 235 technologies

Technology selection and development

“Clustering” and downsizing 157 Remaining

technologies

Trade-off based on a scoring

Scoping Technology Development

2010 2011–2012–2013

129 selected technologies


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Examples of green technologies

Dry metal machining

Replacement of chemical machining by mechanical machining

Bio-fibbers / bio-resins for cabin interiors and secondary structures

Press forming of TS

Metal scrap management for recycling


AL-ALY STL-ALY CRES TITANIUMMG-ALY FILM ADH GL/EP GR/PHKV/EP NOMEX RUBBER LEADPLASTIC SEALING PAINT OILCOPPER EQUIPMENT

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A/C Reference parts

Bill of Materials & Processes

A/C Material & Process cakes

Overall LCA Logic

LCA on Reference

parts

LCA on Reference

parts

Technologies Eco-Statement(current & innovative)

Technologies Eco-Statement(current & innovative)

Combination for A/C

extrapolation

Combination for A/C

extrapolation

A/C Level Eco-Statement

(current & innovative)

A/C Level Eco-Statement

(current & innovative)

Composite10%

Miscellaneous: Copper, bronze,

synthetic5%

Titanium3%

Steel1%

Aluminium81%

Material & Process Technologies


A global approach to assess environmental Impacts: All stages of the product life cycle

Several impact categoriesSeveral actors

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Energy/ Raw Materials /Water..

Air Emissions/Land Use / WaterEffluents/…

22 Multi-criteriaResults:

Identify Environmental burdens

Aeronautic Applications :Compare products & technologies

Analyze key assemblies and equipments to extrapolate to the entire aircraft

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Alum

inium

Compo

sites

?

What is LCA?

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Direct + Indirect Energy Consumtion - kWh

0

1000

2000

3000

4000

5000

6000

RAW MATERIAL MANUFACTURING EOL

ASSY

CLIP

STRINGER

FRAME

SKIN

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Example of LCA: airliner fuselage panel

Aluminium

Paint

Direct & indirect energy consumption (kWh) versus life phaseEndpoint impact for materials and processes

SKIN

FRAMES

STRINGER

CLIP

Metallic fuselage panel

Fuselage panel material mix

FUSELAGE PANEL -AIB (FLP)GaBi 4 process plan: Mass [kg]

ASSEMBLY: CLIP -SKIN(/Stringer)/FRAME (FLP)

ASSEMBLY: FRAME -SKIN/STRINGER (FLP)

XASSEMBLY: SKIN -STRINGER (FLP)

CLIPS (FLP)

FRAME (FLP)

SKIN (FLP)

STRINGERS (FLP)

TITAN BOLT (6,1g per pcs.)

Aluminum Scrap to recycling[b]

Fuselage Panel [b]

ALUMINUM RECYCLING

Fuselage panel LCA model

General aggregated results

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Human health Ecosystemquality

Climate change Resources

AssemblyPrimerCAAProcessesAluminium

Approximate impact reduction

Use of secondary aluminium 71%Reduce energy consumption of CAA

- Total energy (heat and electricity) by 50%

- Chemical process (without electricity)

11.5%

5.2%


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Example of LCA: Air Cooling Unit

AluminiumPTFE BronzeInoxInconelMixVictrexCompositeCarbure

AIR CONDITIONING UNIT (LIEBHERR)GaBi 4 process plan: Mass [kg]

XCooling Power Unit(Liebherr)

PLENUM

AIR CYCLE MACHINE

CONTROL VALVE -TEMPERATURE

HEAT EXCHANGER- DUAL

Heat Exchanger-Reheatercondensor

Water Extractor

Pipe

DE: Steel sheet 1.5mm el.zinc plated (0.01mm; 2s) PE

Other mechanical Parts

DIRECT + INDIRECT CO2 EMISSIONS (KG)

0,0

50,0

100,0

150,0

200,0

250,0

300,0

350,0

400,0

RAW MATERIAL MANUFACTURING EOL

WATER EXTRACTOR

HEAT EXCHANGER RE HEATERCONDENSOR

HEAT EXCHANGER DUAL

TEMPERATURE VALVE CONTROL

AIR CYCLE MACHINE

PLENUM

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Acidification Potential (AP)

Eutrophication Potential (EP)

Global Warming Potential (GWP

100 years)

Photochem. Ozone Creation

Potential (POCP)

Primary energy from resources

Other mechanical parts

Water Extractor (N/A)

PLENUM

Pipe (N/A)

Heat Exchanger-Reheat. condensor

HEAT EXCHANGER- DUAL

CONTROL VALVE - TEMPERATURE

AIR CYCLE MACHINE

Air cooling unit material mix

Air Cooling Unit LCA model

Primary Energy and impact categories GWP, AP, EP and POCP Direct and indirect CO2 emissions (kg) versus life phase

Dual Heat Exchanger

Plenum and Check ValveAir Cycle

MachineTemperature Check Valve

Water ExtractorRe-heater/Condensor TCV ductApproximate

impact reduction

Use of secondary aluminium 54%Reduce scrap rate by 10% (Al and steel) 8%Improvement of surface treatment process:

- Chemical anodizing (no electricity)

- Better control / lower temperature

4.9%

Up to 8%

Air Cooling Unit


Databases 11

EDA LCA Platform

Commercial Aerospace(CS EDA developed)

ToolsExpert

GABI ATALYS(Airbus)

InterfaceWRAPPER

Graphical User friendly Interface (GUI) visually communicative (JAVA)

Non-expert

ARCHITECTURE


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EDA Overall Eco-statement Planning

WP 3.1.1 LCA tools

WP 3.1.2 Current Eco-Statement

WP 3.1.3 Final Eco-StatementReference A/C

Coming from vehicle ITDsConceptual A/C

Coming from vehicle ITDs

EcoEco--assessment of current / assessment of current / innovative technologies to be innovative technologies to be carried out on a regular basiscarried out on a regular basis

Conceptual A/C Reference A/C

201420132012


Thank you for your attention

Questions?

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Inventory flows Emissions Impacts Damages

Inve

ntor

y D

atab

ase

Life Cycle Inventory

Inventory Results

Mid-pointCategories

End-point Categories

Depletion of resources

Water, air and soil emissions:- CFC- Pb- Cd- PAH- VOC- DDT- CO2- SO2- NOx- Phosphates- Dust

Waste mass production


Waste production

- Ozone layer depletion- Greenhouse effect- Heavy metals in air- Carcinogenics- Pesticides- Summer smog- Winter smog- Acidification- Eutrophication

Different methods for impact /damage calculation: CML2001, IMPACT2002+ , RECIPE, …Different methods for impact /damage calculation: CML2001, IMPACT2002+ , RECIPE, …

Human Health


Waste production

Climate Change

Ecosystem Quality

What is LCA?

Impa

ct D

atab

ase

Impa

ct D

atab

ase

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Xcharacterization) (impact factors)

Xend-point factors

Outputs Flows:

Energy (warming)Liquid effluentsGaseous effluentsSolid waste …

Inputs Flows:

Raw materialsWaterEnergy …

Xemission factors

LCA tools and databases perimeter