GREEN BY DESIGN Pratt

1
GREEN BY DESIGNPratt Whitneys Green Engine
Program

• Columbia University
• Industrial Ecology Course
• February, 2001
• Pratt Whitney
• Bob Tierney

Pratt Whitney - United Technologies Corporation
2
Todays topics...

• United Technologies Corporation
• Pratt Whitneys Green Engine Program
• Our conception of Life Cycle Assessment
• Elimination of hazardous materials from life
  cycle
• Strategic thoughts on implementing green

3
Progress !!
Lead air emissions 98 decrease 1970-95 Lead
in childs 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
4
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
5
The Master Equation
Global Envi. Impact
Unit of Waste Unit of Resource
Resource use Person
Population
X
X
6
Drivers for Green

• State of the environment
• Customers
• Bottom line (Green )
• Top Line Growth
• Wall St.
• Politics/ Regulations
• UTC Policy/ 10X Goals

7
Local Restrictions Increasing at an Accelerating
Rate
Based on 594 airports in Boeing database
http//www.boeing.com/assocproducts/noise/list.ht
ml
2/22/00
25
8
Green Engine Program is structured as a matrix
organization
Design
Suppliers
Management
Green Factory
Technology
Customer Requirements/ Communications
9
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.
Use Service
Reuse
Remanufacture
Revert
10
CO2 Emissions
Factory vs. Use
55X
11
Develop Process Map with the Goes-Ins and the
Goes-Outs
Inputs
Outputs
Process or Activity
Product or Service

• Actions of People,
• Equipment, Machines
• Reactions of
• Chemicals and Materials

• Raw Materials
• Chemicals
• Energy
• Fuels
• Electricity

By-products

• Injuries
• Illnesses
• Inefficiencies
• Air Emissions
• Water Discharges
• Solid/Liquid Waste

12
Tap Into Existing Data Sources
All Other Injuries
Ergonomic Injuries 57
43
Material Handling 37
Maintenance Service 11
Manufacturing Assembly 26
Injuries by type and operation
Hazardous waste sent off site by process source
13
Is it Good, Bad or Ugly?
14
Elements of a Green Engine
Vision Pratt Whitney sets the Standard for
Green
Has lowest possible Noise Impact
Has the lowest possible Emission Impact during
use
Is manufactured and serviced using Green Processes
Is designed with Human Factors in mind
Is Material Efficient (Metal Buy-to-fly, Propella
nt 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
15
Understanding Impacts is Key to Continuous
Improvement
Job Ticket/ SRD/ CRD
LCA
Goals
Design Specifications
Procurement Process
Design Standard Work
Operating Procedures
Distribute
Supplier Manufacturing
PW Manufacturing
Use
Service
End of Life
Environment, Safety, Natural Resources Impact
16
Knowing Where to Apply the Green Pressure Points
Technology Team
Customer Reqmt Team
Supplier Team
Job Ticket/ SRD/ CRD
LCA
Goals
Design Specifications
Procurement Process
Design Standard Work
Design Team
Operating Procedures
Green Factory Team
Distribute
Supplier Manufacturing
PW Manufacturing
Use
Service
End of Life
Environment, Safety, Natural Resources Impact
17
LCA as Part of Integrated Program Deployment (IPD)
PRODUCT LIFE CYCLE ASSESSMENT
TECHNICAL SUPPORT
Product Requirements
Market Feedback Analysis
EHS ANNUAL PLANNING EVALUATION
Aspects Impacts
Objectives Targets
18
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)
19

• What is a Life Cycle Assessment?
• Qualitative process used to assess EHS
• impacts of product during its lifecycle
• What does it provide?
• Relative magnitude of EHS impacts
• Areas of information gaps
• Priorities for green design
• Priorities for green technology development
• And.
• Raises consciousness of organization

20
Materials/ Processes of Concern
21
MATERIALS OF CONCERN FOR GAS TURBINE AND ROCKET
PROPULSION SYSTEMS

• Materials Of Concern
• Hazardous Materials Index
• Product Comparisons
• Standard Work
• Green Technology Goals
• Summary

22
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

23
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.

24
Materials of Concern
Prohibited Restricted To Be Reduced
Arsenic compounds Asbestos Benzene Beryllium Cad
mium compounds Chlorinated solvents Ethyl
alcohol Ethylene glycol ether compounds Formaldehy
de Mercury compounds Methanol (methyl
alcohol) Methylene chloride Class I ozone
depleting substances Radioactive materials,
including Thoriated (TD) nickel Toluene
diisocyanate
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,
2-butanone) Methyl iso-butyl ketone (MIBK,
4-methyl-2-pentanone) Phenol Styrene Toluene Xylen
e
Acetone Ammonia Butyl alcohol Ethyl
benzene n-Hexane Hydrochloric acid Isocyanates n-m
ethyl-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,
4-Trimethylbenzene

25
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 TnP/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

26
Hazardous Materials Index

• Implementation
• Establish metrics/set goals
• Establish signoff/approval protocols
• Control via standard work

27
Technology Opportunity
28
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

29
Materials of Concern List with Specification
Number
30
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

31
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

32
Rod Elkington, Chairman Tomorrows economy
will be about increasing returns where we learn
to exploit virtuous cycles rather than manage
vicious ones.