Ecodesign by J Lery (Dassault)

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J Lery (Dassault) presentation at the Ecodesign roundtable organised by Clean Sky at PAris Air Show 2011

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Ecodesign by J Lery (Dassault)

  1. 1. Round TableEco-Design & LCA in aeronautics Le Bourget, June 20th, 2011LifeCycle Assessment of Materials and Processes J. Lery – Dassault Aviation
  2. 2. Clean Sky Objectives – Eco-Design ITD 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 cycleECO-DESIGN ITD(Airframe part) 2 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
  3. 3. Eco-Design for Airframe (EDA) Objectives• Development of A/C technologies to reduce environmental impacts during out-of-operation phases of the A/C lifecycle Reduction of Reduction of inputs and inputs and outputs outputs Technology Technology areas along areas along the lifecycle the lifecycle 3 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
  4. 4. EDA Overall Logic to TE Evaluation tools - LCAReqts Eco-Statement - LCA SYSTEM Final Eco-St. - LCA GuidelinesSoA Scoping Selection for development TECHNOLOGY Development maturation Selection for demonstration Demo. Def.DEMONSTRATION Demonstration Year 1 Year 2 Year 3 Year 4 Year 5 Year 6 Year 7 2009 2010 2011 2012 2013 2014 4 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
  5. 5. Technology selection and developmentState of the art 235 technologies “Clustering” and downsizing 157 Remaining technologies Trade-off based 129 selected on a scoring technologies Scoping Technology Development 2010 2011–2012–2013 5 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
  6. 6. Examples of green technologiesDry metal machiningReplacement of chemical machining bymechanical machiningBio-fibbers / bio-resins for cabininteriors and secondary structuresPress forming of TS Metal scrap management for recycling 6 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
  7. 7. Overall LCA Logic Technologies A/C Reference Eco-Statement parts (current & innovative) LCA on ReferenceMaterial & Process parts Technologies Combination for A/C extrapolation A/C Level Eco-Bill of Materials & A/C Material & Statement (current & innovative) Processes Process cakes Miscellaneous: Copper, bronze, synthetic Composite 5% 10% Titanium 3% Steel 1% 7 AL-ALY STL-ALY CRES TITANIUM Aluminium MG-ALY FILM ADH GL/EP GR/PH 81% KV/EP NOMEX RUBBER LEAD PLASTIC SEALING PAINT OIL COPPER EQUIPMENT 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
  8. 8. What is LCA?1 A global approach to assess environmental Impacts: Aeronautic Applications : 3 All stages of the product life cycle Compare products & technologies Several impact categories Several actors es um ? s it ini o Energy/ Raw Materials /Water.. mp um Co Al Analyze key assemblies and equipments to extrapolate to the Air Emissions/Land Use / entire aircraft WaterEffluents/…2 Multi-criteria Results: Identify Environmental burdens 8 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
  9. 9. Example of LCA: airliner fuselage panel FUSELAGE PANEL -AIB (FLP) Ga Bi 4 process pla n: Ma ss [kg] TITAN BOLT (6,1g per pcs.) ASSEMBLY: SKIN - X STRINGER (FLP) SKIN (FLP)FRAMES STRINGERS (FLP) STRINGER Aluminium SKIN FRAME (FLP) ASSEMBLY: FRAME - SKIN/STRINGER (FLP) Paint CLIPS (FLP) ASSEMBLY: CLIP - SKIN(/Stringer)/FRAME (FLP) Aluminum Scrap to recycling [b] CLIP Fuselage Panel [b] Fuselage panel material mix ALUMINUM RECYCLING Fuselage panel LCA model Metallic fuselage panel Approximate impact reduction General aggregated results Use of secondary aluminium 71% Reduce energy consumption of CAA 100% - Total energy (heat and electricity) by 50% 11.5% 90% Direct + Indirect Energy Consumtion - kWh - Chemical process (without electricity) 5.2% 80% 6000 70% 5000 60% Assembly Primer 4000 ASSY 50% CAA CLIP Processes 3000 STRINGER 40% Aluminium FRAME 2000 SKIN 30% 20% 1000 10% 0 0% RAW MATERIAL MANUFACTURING EOL 9 Human health Ecosystem quality Climate change Resources Direct & indirect energy consumption (kWh) versus life phase Endpoint impact for materials and processes 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
  10. 10. Example of LCA: Air Cooling Unit AIR CONDITIONING UNIT (LIEBHERR) Ga Bi 4 process plan: Mass [kg] Air Cooling Unit Dual Heat Exchanger Air Cooling Unit LCA model Aluminium PLENUM Cooling Power Unit X (Liebherr) PTFE Bronze AIR CYCLE MACHINE Inox Inconel Mix CONTROL VALVE - TEMPERATURE Victrex HEAT EXCHANGER- DUAL Composite Heat Exchanger-Reheater Carbure condensor Air cooling unit material mix Water Extractor Pipe Plenum and Approximate TCV duct impact DE: Steel sheet 1.5mm el.Re-heater/Condensor Water Extractor Temperature Air Cycle Check Valve zinc plated (0.01mm; 2s) PE Other mechanical Parts Check Valve Machine reduction Use of secondary aluminium 54% Reduce scrap rate by 10% (Al and steel) 8%100% Improvement of surface treatment process: 90% 80% - Chemical anodizing (no electricity) DIRECT + INDIRECT CO2 EMISSIONS (KG) 4.9% 70% Other mechanical parts 400,0 - Better control / lower temperature Up to 8% 60% Water Extractor (N/A) 50% PLENUM 350,0 WATER EXTRACTOR 40% Pipe (N/A) 300,0 HEAT EXCHANGER RE HEATER 30% Heat Exchanger-Reheat. condensor CONDENSOR HEAT EXCHANGER- DUAL 250,0 HEAT EXCHANGER DUAL 20% CONTROL VALVE - TEMPERATURE 200,0 10% TEMPERATURE VALVE CONTROL AIR CYCLE MACHINE 0% 150,0 AIR CYCLE MACHINE Acidification Eutrophication Global Warming Photochem. Primary energy Potential (AP) Potential (EP) Potential (GWP Ozone Creation from resources 100,0 100 years) Potential PLENUM (POCP) 50,0 Primary Energy and impact categories GWP, AP, EP 0,0 RAW MATERIAL MANUFACTURING EOL 10 and POCP Direct and indirect CO2 emissions (kg) versus life phase 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
  11. 11. EDA LCA Platform ARCHITECTURE Interface Graphical User friendly Interface (GUI) visually communicative (JAVA) Non-expert Tools WRAPPER ATALYS GABI (Airbus) Expert Databases Aerospace Commercial (CS EDA developed) 11This 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
  12. 12. EDA Overall Eco-statement Planning2012 2013 2014 WP 3.1.1 LCA tools WP 3.1.2 Current Eco-Statement Reference A/C WP 3.1.3 Final Eco-Statement Coming from vehicle ITDs Conceptual A/C Coming from vehicle ITDs Conceptual A/C Reference A/C Eco-assessment of current / innovative technologies to be carried out on a regular basis 12 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
  13. 13. Thank you for your attention Questions? 13This 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
  14. 14. What is LCA? Life Cycle Inventory Mid-point End-point Inventory X Results X Categories X Categories emission characterization) end-point factors (impact factors) factorsInventory flows Emissions Impacts DamagesInputs Flows: Depletion of resources Depletion of resources Depletion of resourcesRaw materials Water, air and soilWater emissions: Inventory Database - CFC - Ozone layer depletion Human Health Impact Database Impact DatabaseEnergy … - Greenhouse effect - Pb - Cd - Heavy metals in air - PAH - Carcinogenics - VOC - Pesticides Ecosystem Quality - DDT - Summer smogOutputs Flows: - Winter smog - CO2 - SO2 - AcidificationEnergy (warming) - Eutrophication Climate Change - NOxLiquid effluents - PhosphatesGaseous effluents - DustSolid waste … Waste mass production Waste production Waste production LCA tools and 14 databases Different methods for impact /damage calculation: perimeter CML2001, IMPACT2002+ , RECIPE, … 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

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