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

1. Round Table
Eco-Design & LCA in aeronautics
Le Bourget, June 20th, 2011
LifeCycle Assessment of Materials and
Processes
J. Lery – Dassault Aviation

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 cycle
ECO-
DESIGN ITD
(Airframe part)
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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
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4. EDA Overall Logic
to TE
Evaluation tools - LCA
Reqts
Eco-Statement - LCA
SYSTEM Final Eco-St. - LCA
Guidelines
SoA
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
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5. Technology selection and development
State 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
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6. Examples of green technologies
Dry metal machining
Replacement of chemical machining by
mechanical machining
Bio-fibbers / bio-resins for cabin
interiors and secondary structures
Press forming of TS
Metal scrap
management
for recycling 6
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7. Overall LCA Logic
Technologies
A/C Reference Eco-Statement
parts (current & innovative)
LCA on
Reference
Material & 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%
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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
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8. What is LCA?
1 A global approach to assess environmental Impacts: Aeronautic Applications :
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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
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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
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Human health Ecosystem
quality
Climate change Resources
Direct & indirect energy consumption (kWh) versus life phase
Endpoint impact for materials and processes
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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
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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)
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12. EDA Overall Eco-statement Planning
2012 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
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13. Thank you for your attention
Questions?
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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) factors
Inventory flows Emissions Impacts Damages
Inputs Flows: Depletion of resources Depletion of resources Depletion of resources
Raw materials Water, air and soil
Water emissions:
Inventory Database
- CFC - Ozone layer depletion Human Health
Impact Database
Impact Database
Energy … - Greenhouse effect
- Pb
- Cd - Heavy metals in air
- PAH - Carcinogenics
- VOC - Pesticides Ecosystem Quality
- DDT - Summer smog
Outputs Flows: - Winter smog
- CO2
- SO2 - Acidification
Energy (warming) - Eutrophication Climate Change
- NOx
Liquid effluents - Phosphates
Gaseous effluents - Dust
Solid waste …
Waste mass production Waste production Waste production
LCA tools and 14
databases Different methods for impact /damage calculation:
perimeter CML2001, IMPACT2002+ , RECIPE, …
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