Materials 4I03/6I03/SEP 6I03

Materials 4I03/6I03

SEP 6I03

  Sustainable Manufacturing Processes

Course Information 2015-2016

Instructor:  Dr. Neslihan Dogan, JHE-213B, x23270, dogann@mcmaster.ca
 Office Hours: Monday & Thursday 11am-12pm, or by appointment
Course website: Avenue to Learn

Calendar Description:

MATLS 4I03  SUSTAINABLE MANUFACTURING PROCESSES
Sustainable development, materials cycles, methods for measuring environmental impact, life cycle analysis, waste treatment and recycling technologies. 
Two lectures, one tutorial (one hour); first term
Prerequisite: Registration in final or penultimate year of any Materials Engineering program or permission of instructor or registration in Level IV or above in other Engineering program.

Learning Outcomes

Evaluation Level

  • Make a recommendation, including justification for the most “sustainable” method of processing that could be used to process or produce a given object or material, discussing the merits and drawbacks of the processing steps in terms of at least three of the most significant sustainability measures.

Synthesis Level

  • Describe methods to lower GWP and other ecological impact factors within the materials cycle for a specified industry, material or product.
  • For a selected industry, material or product obtain data on the extent of dematerialization, EI, GWP, AP and Factor X.

Application Level

  • Calculate personal ecological footprint.
  • Calculate for one industry, one material or product:  MI, EI, GWP, AP and Factor X.
  • Evaluate a LCA for one industry, one material or product.
  • Explain how allocation strategies affect the impact.

Comprehension Level

  • Describe the “limits to growth”, the uses of LCA, describe a process for completing a LCA, describe relationships between MI, EI, GWP, AP and Factor X, describe the need and basis for the ISO and the purposes of the ISO 14000 code.

Knowledge Level

  • List key data regarding world population, western and developing world standards of living, the availability of natural resources and environment.
  • Acknowledge the tensions between the demands of society and the availability of nature to sustain these demands.
  • Give definitions for:

“Conventional Economic Growth Model” vs. “New Growth Model”
“Rival” vs. “excludable” with reference to intellectual property
Complexity
Dematerialization
The Materials Cycle
Eco-Efficiency
Life Cycle Analysis
“Cradle-to-Grave Analysis”
“Cradle-to-Gate Analysis”
Boundaries
Allocation and Allocation Strategies
Impact Factor
Factor 4, 10 and X.
Stakeholders

Evaluation (Matls 4I03)

In

Individual Assignments 20%
Team Project* 40%
In Class Test 40%

*Students are to form teams of 2 people of their own choosing. One team of 3 will be permitted only if there are an odd number of students in the class; the project will need to compare 3 different options in this case.

Evaluation (Matls 6I03 & SEP 6I03)

Individual Assignments 20%
Individual Project 50%
In Class Test* 30%

*The examination will be more difficult than the Matls 4I03 examination.

Individual Assignments (5% each):
The assignments are to be submitted to the course dropbox, JHE-213 one week after they are assigned. Grades will be deducted for late assignments. 

Project

Prepare a 20-page (double-spaced, including Figures and Tables) report on sustainable manufacturing for an industry, process or product. Make a recommendation, with justification, of the most sustainable method(s), including at least three sustainability measures. The report must include an LCA that compares at least 2 competing process.  The report must discuss the results, and include a sensitivity analysis for the appropriate aspects of the LCA.

Data for the LCA can be taken from the literature, but the calculation and the analysis must be done with the methodology described in the lectures. Commercial software may not be used for the calculation.

The report is to be submitted to the course dropbox, JHE-213 by 5 pm on Dec 8.  Grades will be deducted for late reports.  The reports must also be submitted electronically to Avenue to Learn by the same deadline; only one submission is required per team. 

In-class tests:
There will be three in-class tests throughout the term. They will deal with knowledge of sustainability issues, methodology and terminology.


Sep. 8, Introduction/Outline
Handout is posted on the website.

Sep. 10, Population & Environment
Living Planet Reports, 2012, 2010 & 2006 are available at the World Wildlife Fund website: http://wwf.panda.org/about_our_earth/all_publications/living_planet_report/2012_lpr/

http://www.wwf.ca/newsroom/reports/living_planet_report_2010.cfm

http://wwf.panda.org/about_our_earth/all_publications/living_planet_report/living_planet_report_timeline/lp_2006/

Sep. 14, Ingenuity Gap
Homer-Dixon, T.
The Ingenuity Gap, Homer-Dixon, T.
Copyright (C) 2001 Vintage Books Canada
Ch. 1 "Careening into the Future"
Ch. 6 "Glimpsing the Abyss"
Ch. 7 "Unknown Unknowns"
Ch. 9 "Ingenuity and Wealth"

Sep. 15, The Materials Cycle
"Foundations of Sustainable Resource Processing"
Herbertson, J. & Sutton, P.
Green Processing Conference, Cairns, Qld, 29-31 May 2002
Copyright (C) 2002 Unsourceable

Global Materials Flows in Minerals Processing
Algie, S.H.
Green Processing Conference, Cairns, Qld, 29-31 May 2002
Copyright (C) 2002 Unsourceable

Sep. 17, Eco-Efficiency (Part A)
DeSimone, L.D., et al.
Eco-Efficiency: The Business Link to Sustainable Development, 

Oct. 12-16 – No class

Oct. 19, Open Loop Recycling in LCA (Part A)
“The value of Recycling to Society and its Internalization into LCA methodology
J.P. Birat, La Revue de Metallurgie, 103, 2, 2006, Cambridge University Press US

Oct. 20, In-class test 2

Oct. 22, Open Loop Recycling in LCA (Part B)
“The value of Recycling to Society and its Internalization into LCA methodology
J.P. Birat, La Revue de Metallurgie, 103, 2, 2006, Cambridge University Press US

Oct. 26, Impact Assessment in LCA
“The Eco-Indicator 99, A damage oriented method for Life Cycle Assessment”
M. Goedkoop & R. Spriensma, 2001, PRE consultants

Oct. 27, LCA Case Study – Pb & Zn Production
"An Environmental Assessment of Lead and Zinc Production Processes"
Norgate, T.E. & Rankin, W.J.
Green Processing Conference, Cairns, Qld, 29-31 May 2002
Copyright (C) 2002 Unsourceable

Oct. 29, Stakeholders I
Stakeholder Politics, Social Capital, Sustainable Development and the Corporation, Robert Boutilier, 2009, Greenleaf Publishing, available in pdf format for ~$45.00 from http://www.greenleaf-publishing.com   or at Amazon for $20

Nov. 2, Stakeholders II
Stakeholder Politics, Social Capital, Sustainable Development and the Corporation, Robert Boutilier, 2009, Greenleaf Publishing, available in pdf format for ~$45.00 from http://www.greenleaf-publishing.com   or at Amazon for $20

Nov. 3, Guest Lecture

Nov. 5, Strategic Sustainable Development
"Factor X for Subtle Policy Making"
Robert, K-H., et al
Greener Management International, Vol.31, Autumn 2000
Copyright (C) 2000 Greenleaf Publishing Ltd.

"Tools and Concepts for Sustainable Development, How Do They Relate..."
Robert, K.-H.
Journal of Cleaner Production, Vol.8, 2000
Copyright (C) 2000 Elsevier Science

Nov. 9, Vision 2050 I
Vision 2050 is available at http://www.wbcsd.org/vision2050.aspx

Nov. 10, Vision 2050 II
Vision 2050 is available at http://www.wbcsd.org/vision2050.aspx

Nov 12, In-class test 3

Nov 16-Dec 8, Guest lecturers from Industry
Handouts are posted on the website. Depending in the availability of guest lecturers, there could be changes in the schedule.

 

The instructor and university reserve the right to modify elements of the course during the term. The university may change the dates and deadlines for any or all courses in extreme circumstances. If either type of modification becomes necessary, reasonable notice and communication with the students will be given with explanation and the opportunity to comment on changes. It is the responsibility of the student to check his/her McMaster email and course websites weekly during the term and to note any changes.

Academic Integrity

“Academic dishonesty consists of misrepresentation by deception or by other fraudulent means and can result in serious consequences, e.g. the grade of zero on an assignment, loss of credit with a notation on the transcript (notation reads: “Grade of F assigned for academic dishonesty”), and/or suspension or expulsion from the university.

It is your responsibility to understand what constitutes academic dishonesty.  For information on the various kinds of academic dishonesty please refer to the Academic Integrity Policy, specifically Appendix 3, located at http://www.mcmaster.ca/senate/academic/ac_integrity.htm

The following illustrates only three forms of academic dishonesty:

  1. Plagiarism, e.g. the submission of work that is not one’s own or for which other credit has been obtained.   Work of others must be referenced in the text by name or with superscripted numbers, and the reference information collected at the end of the report.
  2. Improper collaboration in group work.  Assignments must be done individually.  The group projects are to be an equal collaboration by the students in the group.
  3. Copying or using unauthorized aids in the examination.

Students will be required to submit their written report to Turnitin.com to ensure that the work has proper citation of previous work.