Mike Pitts EDN mar 2010

Knowledge Transfer Networks Accelerating business innovation; a Technology Strategy Board programme

Sustainable Design for Innovation in the Chemistry-Using Industries

Mike Pitts

Chemistry Innovation


Knowledge Transfer Networks

etc..

http://www.bis.gov.uk/


The Chemistry-Using Industries

Source: 2007 R&D Scoreboard of Top 850 UK Companies - published by BERR/DIUS

Global Sales >£700 billion; GVA >£200billion; Directly Employs >2.3million

Product Life-Cycle

idea

materials

earthsunlight

manufacture

distribution

retaildisposal

use of product


Improved Efficiency

70

80

90

100

110

120

130

140

150

160

1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004

Year

Re

lati

ve

Ind

ex

(1

99

0 =

10

0)

Greenhouse Gas Emissions

Energy Consumption

Production

source: CEFIC/European Environment Agency

EU Chemicals Industry (incl. pharma)


Low-Carbon Solutions

For every unit of GHG emitted directly and indirectly by the chemical industry, this industry enabled 2-3 units of emission savings via the products and technologies provided to other industries and consumers.

Under 2030 scenarios, this could reach 4:1

The most significant savings came from:

marine antifouling coatingssynthetic textilesautomotive plasticslow-temperature detergentsplastics used in piping

insulating foamsagrochemicalslightingplastic packagingengine efficiency

idea

materials

earthsunlight

manufacture

distribution

retaildisposal

use of product

Product Life-Cycle

ideas

materials

earthsunlight

manufacture

distribution

retaildisposal

use of product

waste

energy

emiss

ions

Product Life-Cycle


Sustainability Drivers

Pressure from: regulators/legislation customers public shareholders/lenders

Reduce costs Feedstock conservation Market positioning – new markets, leadership and reputation Innovation – understanding customer’s needs Developing competitive advantage by solving other people’s

sustainability problems

Paradigm change: from plant/product to whole life cycle from unit operation to whole system from process and product to service

How to do it?Why do it?


Business Case

AkzoNobel state: “Social and environmental trends are re-shaping the competitive arena, and thus our customers’ futures.”18% of sales come from sustainable products with the aim to have 30% by 2015

Proctor & Gamble plans to generate >$50 billion sales from products with reduced environmental impact over the next three years.This was recently revised up from the 2007 target of $20 billion reflecting a strengthened pipeline of initiatives.

GE’s ‘ecomagination’ portfolio has grown from 17 to more than 80 products in 2009. 2008 revenues reached $17 billion, an increase of 21% over the prior year.


For every tonne of household waste that we throw away, there's a further 5 tonnes

of materials that have been used in the manufacturing of the products consumed

Don't throw anything away. There is no 'away' - Shell advert

90% of all products are waste within 6 months of purchase


Water

by 2020 we will need 17% more water by 2020 we will need 17% more water than is currently availablethan is currently available

‘‘water is the oil of the 21st century’water is the oil of the 21st century’Dow CEO Andrew LiverisDow CEO Andrew Liveris

‘embedded’ water

content (litres)1 pair of shoes

1 cotton T-shirt

1 hamburger

1 glass of milk

1 cup of coffee

1 microchip (2g)

8000

4100

2400

200

140

32

Source: World Council, UNESCO, DEFRA

about how much a dishwasher uses in a

year


Endangered Elements


Sustainable Design Approaches

Design for life cycle‑• Designing for the total life-cycle of a product should be standard. • Design in biodegradability and low aquatic toxicity. • Design for separation and recovery of materials – plastics, precious metals, etc.

Design for recycle and re use‑• Extend experience of recycling and reusing catalysts, lubricants and solvents.

Efficient process design• Integrating product and process design – holistic approaches.

Reducing material intensity• Reducing the amount of material required to produce a specific outcome. • e.g. micro- and nano-particles formulation; ‘atom-efficiency’ and E-factor

concepts; etc.


Examples


Examples


Roadmap website

www.chemistryinnovation.co.uk/stroadmap


Ship Hull Anti-foul Coating

ProblemShip’s lose sailing performance and are damaged due to barnacles settling onto a vessel's underwater hull. The usual approach is to coat the hull in a biocidal paint.

Technical solutionIntersleek® produces a slippery, hydrophobic, low friction surface onto which fouling organisms have difficulty settling.

Benefits•no leaching of biocides into the sea •reduced fuel consumption•reduced carbon dioxide emissions•reduced wash water treatment costs at drydock•longer intervals between drydock servicing•reduces fuel costs by at least 6%•$2.5 million savings over a five year period for a typical ship

source: Sustainable Technologies Roadmap


ProblemResistance coiled heating elements are widely used. Their manufacture uses a high impact 27 step process and they are energy inefficient.

Technical SolutionA new flat heating element is made by spraying metal alloy oxides onto an insulating base to form a 50 – 250 micron coating.

Benefits lightweight but robust element that can be applied to shaped surfacesreducedup to 40-50% energy savingssafety in use, with lower current densities3-4 stage manufacture1/16th material use50-80 fold reduction in energy during productionavoids of acidic waste streams and open-cast mining of magnesium oxide

Energy Efficient ‘Spray-On’ Heating Elements

source: Sustainable Technologies Roadmap


Sustainable Design Guide

Shows chemistry-using organisations how to build sustainable thinking into their innovation processes

A collection of best practice with a process for how to do it

Linked supporting resources


Workbook Tools

Raw Materials

Manufacture Use

Recycling

Distribute

Raw Materials

Manufacture Use

Recycling

Distribute


Workbook Content


‘Today's problems cannot be solved if we still think the way we thought when we created them’ - Albert Einstein

www.chemistryinnovation.co.uk/stroadmapwww.chemistryinnovation.co.uk/sdg

[email protected]



Mission & Strategy

Mission

To stimulate & support

product and process

innovation

that will deliver

tangible value

for the UK

chemistry-using industries


(external) expert

Impact Assessment

source: Forum for the Future

principles & rules-of-thumb

directional tools

single simple indicators

Life-Cycle Analysis

i.e. life-cycle thinking

e.g. Eco-Innovation compass

& matrix analysis

metrics

early

late

qualitative quantitative

do ‘in-house’


CCaLC lifecycle footprinting


CCaLC lifecycle footprinting

www.ccalc.org.uk

Mike Pitts EDN mar 2010

Design

life cycle

total lifecycle

fromsustainable products

water source

industries source

reputation innovation

improved efficiency

industry enabled2