Environmentally Conscious Design & Manufacturing

1. Environmentally Conscious Design & Manufacturing Class9: Health & Environmental Issues Prof. S. M. Pandit

2. Health and Environmental Issues • Cutting fluids in manufacturing • EPA water quality monitoring • Analytical monitoring tools • Health hazards • Where does it fit? 1

3. Cutting Fluids in Machining Additives: Chlorine, Sulfur, Phosphorus, Biocides, Odorants 2

4. Claimed Benefits of Cutting Fluids • Lubrication • Heat transfer • Chip flushing • ______________________________________ • Increased tool life • Reduced thermal deformation • Improved surface finish • Reduced forces • Corrosion protection of surface • Workpiece cleaner

5. Cutting Fluid Liabilities - 1 • •Fluid disposal due to contaminant build-up • • Fluid performance is time dependent • • Maintenance, disposal, handling, protection, • and acquisition expensive • • Hazardous chemical constituents • • Source of occupational airway disease

6. Cutting Fluid Liabilities - 2 • • Source of contact dermatitis • • Excessive BOD, FOG, Nitrogen, Phosphates • • Expensive pre-treatment prior to disposal • (wastewater currently sent to POTW - changes • to permissible level of contamination being considered - may require additional expensive pretreatment)

7. Cutting Fluid Types(Straight Oils / Soluble Oils) • • Straight oils - Non-emulsifiable. Base oil, • and often fats, veg. oil, & esters. May include extreme • pressure additives such as Chlorine, Sulphur, • Phosphorus. • • Soluble oils - Form emulsion when mixed with water. • Typical concentrations of 3-10% - least expensive. • • Synthetic fluids - Formed from alkaline inorganic & • organic comp. + corrosion inhibitors. Diluted form. • • Semisynthetic fluids - Combo. of synthetic & sol. oil.

8. Straight Oil EP Additives Some suggest that EP additives react with work material - form a barrier film that provides lubrication

9. Straight Oils: Pros and Cons Pros Cons Good lubrication Expensive - hard materials Rancidity & degradation Flammable resistant Good rust protection Smoke prone Low maintenance Health hazard Lack of cooling Viscosity low

10. Straight Oils vs. Water Solubles Straight Oils Water Solubles Degradation resistant High thermal conductivity Good lubrication Good cooling ability Easier to recycle More economical Good surface wettability Better operator acceptance Good rust protection No fire hazard Less oil misting

11. Cutting Fluids in Machining(reducing waste) - Use water-soluble metal working fluids. - Use de-mineralized water make-up - Perform regularly scheduled sump and machine cleaning. Waste Reduction and Recycling Methods

12. EPA Water Quality Monitoring -1 Question: What is happening to groundwater, lakes and rivers? pH Alkalinity Arsenic Asbestos Barium Chromium Cyanide Mercury Nickel Nitrate Selenium Lead Copper • Testing water Inorganics (see epa.gov for complete list)

13. EPA Water Quality Monitoring - 2 Benzene Carbon Tetra Chloride Chloroethylene Styrene Toluene Trichloromethanes Organics

14. Analytical Monitoring Tools Atomic Absorption

15. Mass Spectrometry

16. Mass Spec

20. Where Does It Fit? Manufacturing Source reduction Liquid wastes (cutting fluids) Testing of effluents Waste treatment Recycle / Reuse

21. Homework #3 The following problems are out of the textbook “Industrial Ecology” 1. Problem 8.1 2. Problem 8.2 3. Problem 9.3 Hint: A simple and reasonable technique is to sum the row entries and column entries. An overall rating is given by adding row totals(or the equivalent, column totals) so that the entire matrix is summed. Answer: Design 2 is better than design 1 because design 2 has higher overall score (48 to 43), and the product use rating, and many products have their greatest impact during the in-use stage.