1. Building in
Sustainability
Prof Graham Hillier, CEng, FRSA
Director of Strategy and Futures, CPI
Salford University
27th April 2011
Copyright CPI 2011. All rights reserved

2. Content
• A bit about me
• A bit about the Centre for Process Innovation
• Why sustainable engineering is important
• Engineering for Sustainability Requires a Behaviour Change
• Examples of Sustainable Engineering
• Making the Change

3. A Bit About Me

4. A Bit About Me
• Sponsored undergraduate at Rolls-Royce
• Metallurgy degree at Sheffield University
• PhD on single crystal turbine blades at Cambridge University
• Joined ICI worked in Polymer Films, Advanced Materials, Petrochemicals,
Plastics and Fertilizers. Finished as Strategy Director
• Moved to British Steel/Corus in Business Development, Merger integration
• Became Corus Construction Director
• Joined CPI in Low Carbon Technologies – Included sustainable communities
• Now CPI Strategy and Futures Director

5. A Bit About CPI

6. CPI’s Vision
Vision
• A World Class Innovation Centre supporting the Process Industries
CPI Moves to this Vision by:
• Build Physical Assets that bring together Companies, Universities, Public
Sector Funds and Technology Expertise to develop new products and
processes for the Process Industries
Process Development, Proving and Scale Up

7. Innovation: Technology Readiness Levels (NASA)
BUSINESS TRL 9
ECONOMIC
DEVELOPMENT
SUPPORT TRL 8
(Enterprise) System Test, Launch and Operation
TRL 7
System/Sub-System Development
TRL 6
TECHNOLOGY DEVELOPMENT Technology Demonstration
(CPI) TRL 5
Technology Development
TRL 4
Research to Prove Feasibility TRL 3
RESEARCH
TRL 2
(Universities) Basic Technology Research
TRL 1
CPI Works at Technology Readiness Level 4 Up

8. CPI Technology Development
Sustainable Processing Printable Electronics
• Process and product development
• Organic Displays
• Bio transformation reactions
– Anaerobic digestion – Rigid and Flexible
– Fermentation • Solid State Lighting
– Photosynthesis • Organic PV
– Bio catalysis • Electronic Packaging
– Marine processing
• Barrier Films
• Particulate Processing
– Dispersion
– LCDs
– Crystallisation – Organic PV
– Emulsions and blending – Fuel Cells
• Sustainable Systems • Materials
– Engineering – Printable electronic formulations
– Communities

9. Located at Wilton Centre
Semi technical area
- pilot manufacture
World class
analytical facilities
Modern laboratory
space
Office
accommodation
Land & infrastructure
for manufacturing
32 companies on site

10. Some of the CPI Assets
Bioprocess Lab
National Industrial
Biotechnology Facility
Process
Marine Fermentation Intensification

11. Some of the CPI Assets
SEM
Clean Room
Litho area Mask writer

12. The Sustainability Challenge

13. The Definition of Sustainability
Sustainable Development is development that meets the needs of the
present without compromising the ability of future generations to meet
their own needs […]. In essence Sustainable Development is a
process of change in which exploitation of resources, the direction of
investments, the orientation of technological development and
institutional change are all in harmony and enhance current and future
potential to meet human needs and aspirations.
(WCED, Brundtland Commission ,1987)
Engineering and Built Environment Have Much to Contribute

14. The Principles of Sustainability
Create a balance between:
• Economic Factors
– Creating wealth to do things and continue to do them
• Environmental and Natural Resource Factors
– The impact on the resources we have available
• Societal Factors
– That we have healthy, happy full lives
The Three Factors are Equally Important

15. The Challenge of Sustainability
Dealing with:
• Growing Population
– Inexorably increasing the need for food and shelter
• Growing Affluence
– The amount of emissions rise with affluence and we use more
• Resource Consumption
– There is only a finite resource it will not last for ever
This Puts Immense Stress on a Finite System

16. WHY SUSTAINABLE
ENGINEERING IS IMPORTANT?

17. Life Expectancy
Life Expectancy
Massachusetts, US Historical Statistics
85
80
75
Life Expectancy in Years
70
65
60
55
50
45
40
35
1850 1860 1870 1880 1890 1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000
Doubled in 150 Years in Developed World
Developing World will follow

18. Carbon Dioxide in the Atmosphere Rises with Population
Carbon Dioxide Concentrations Year on Year
(Mauna Loa Observatory, Hawaii)
390 7000
370 6000
Atmospheric Carbon Dioxide (ppmv)
350 5000
Population (Millions)
330 4000
310 3000
290 2000
270 1000
250 0
1830 1880 1930 1980
Carbon Dioxide Emissions (ppmv) Population
Source: Mauna Loa Observatory plus historic data from ice cores

19. Food Prices are rising
European Wheat Price Year on Year
200 7000
180
6000
160
WHEAT PRICE IN $/tonne
140 5000
Population in Millions
120
4000
100
3000
80
60 2000
40
1000
20
0 0
1259 1359 1459 1559 1659 1759 1859 1959
Actual 179 pt Moving Average 49pt Moving Average Population

20. Carbon Dioxide Emissions Rise with GDP but….
Carbon Dioxide Emissions per Person v GDP per Person By Country
50
45 Qatar
Carbon Dioxdie Emission per Person (t /year)
40
35
l?
Oi
30 Bahrain
25
Kuw ait
United Arab Emirates
20 Luxembourg
itioning?
United States
Air Cond
Australia
15 Canada
Saudi Arabia Singapore
Estonia
OmanCzech Republic Finland Norw ay
10 Netherlands
Germany
Japan Kingdom Republic of Ireland
Libya SouthIsrael
Korea Greece United Denmark
Poland
South Africa
Slovakia Cyprus
Slovenia New Zealand Austria
Spain European Union
Italy Belgium Iceland
Malaysia Hungary
Bulgaria Montenegro Portugal France Sw eden Sw itzerland
5 Serbia andCroatia Hong Kong
Venezuela
Lebanon
Romania
ThailandMexico
World
Lithuania
Jordan Chile
Argentina
Turkey
Algeria Panama
Latvia
Egypt Brazil Republic
Dominican
Tunisia
Ecuador
0 PakistanCosta Rica
SriEl
Colombia
Indonesia
Morocco
NigeriaUruguay
IndiaLanka
Vietnam e
Zimbabw
KenyaSalvador
Philippines
Guatemala
Peru
Angola
Yemen
Bangladesh
Ghana
Tanzania
Sudan
Cameroon
0 10 20 30 40 50 60 70 80
GDP per Person ('000 US Dollars 2005)
Source data: US Statistics Service and UK
There seems to be a levelling out at 7.5 t/yr to 10 t/yr

21. Population Growth Alone Will Increase Atmospheric
Carbon Dioxide Concentration Significantly
Total Annual
Average CO2 Increase over
Population Human CO2
Case Emissions per 2005 Base
(billion) Emissions
Person (t/yr) Case (bn t/yr)
(bn t / yr)
Base Case 2005 6.6 3.6 24
Rich World 2005
6.6 7.5 50 26 (108%)
Population
Base Case 2050
9 3.6 33 9 (38%)
Population
Rich World 2050
9 7.5 67.5 43.5 (180%)
Population
Dealing with this Much Carbon Dioxide is a Challenge

22. Earth Resource Balance Since 1850
Incoming Energy
Extract Resource
Refine Resource Air Emission
Earth Waste
Water Emission
Use Resource
Resources Used
Scrap Resource
Resource Use exceeds Incoming Energy

23. Resource Availability
Element Available Resource Recycling Rate
Indium 4-13 Years 0%
Silver 9-29 Years 16%
Lead 8-42 Years 72%
Antimony 13-30 Years -
Tin 17-40 Years 26%
Uranium 19-59 Years 0%
Zinc 36-46 Years 26%
Gold 36-45 Years 43%
Nickel 57-90 Years 35%
• Neodymium, Dysprosium, Terbium – Vital to high power magnets
• Lithium, Lanthanum – Vital to high power batteries
• 93% of world rare earth metals come from China
• Availability is falling because regional use is rising!
Source: New Scientist, May 2007, Chemistry World Jan 2011
Many Important Elements Our ‘Renewable’ Technologies Need
Are in Short Supply

24. There is a Strong Belief that Oil Production is Peaking
Source: Hubbert Model From Association for the Study of Peak Oil, 2008
It is Highly Likely That Oil Production Will Peak in the Near Future

25. Resource Demand in A Simple Equation
CO2 Emissions = Population x Gross Domestic Product x Energy Used x CO2 Emission
Population GDP Energy Used
Waste = Population x Gross Domestic Product x Resource Used x Waste Made
Population GDP Resource Used
We Need to Become More Efficient in Our Use of Resources
An 80% Reduction comes from Increased Efficiency or Less Activity
Based on work by Shell scenario planning group

26. So What Do We Have to Do..
• Develop more sustainable processes
• Use resources more efficiency
• Improve the efficiency of our processes
• Look at the efficiency of integrated systems
• Convert wastes to products
• Convert batch processes to continuous ones
Top Six are Increasingly Strong Political and Economic Drivers
Bottom Twois a Our Areas of Strength
There are Lot We Can Do

27. ENGINEERING FOR
SUSTAINABILITY REQUIRES A
BEHAVIOUR CHANGE

28. Approaches to Improved Energy Efficiency, Resource
Efficiency and Carbon Reduction
Reduce use of resources
Reduces
• Resources Consumed
Make sure operational resource use • Cost
is as low as possible • Emissions
• Wastes
Use highly efficient conversion
technologies Increases
• Efficiency of Resource Use
Add on additional technologies
Requires
• A Different Way of Thinking
• Less Conventional Technology
Significant Improvements can be Made

29. Sustainability in Practice: A Schematic Model
Assembled
Raw Material Component System Product End of Life
Recycle Recondition Re-use Re-furbish
Resource Efficient Flexible & Adaptable Design

30. EXAMPLES OF SUSTAINABLE
ENGINEERING AND
CONSTRUCTION

31. Plastic Film Production
Stage 40% Prime 60% Prime
Produce New
Polymer Value, % Value, %
100t Capacity Tonnes Tonnes Value, £
£/t Pass £ Pass
Convert to New Polymer (20) 46 (920) 64 (1280)
Film
Prime Product 100 40 40 4000 60 60 6000
Edge Trim (10) 10 10 (100) 10 10 (100)
Failed Edge Prime Failed
50 50 30 30
Product Trims Product Product
Recycle (10) 90 54 (540) 90 36 (360)
Waste 5 10 6 30 10 4 20
Recycle Waste Customer
Total Value 2470 4280
20% Operational Improvement Gives 75% Value Increase

32. Baffle Reactor
Batch to Continuous
• Lower inventory
• Make what you need
• Plug flow so easy to clean
• Highly efficient mixing
• Capital down up to 50%
• Operating cost down up to 90%
Lower Capital and Operating Cost. Less Resource use and Less
Waste

33. Pump Impeller
Steel to Plastic
• Lower capital cost
• Less material
• More hydrodynamic efficiency
• Smaller motor or higher volume pumped
• Quieter in use
Greater Efficiency in Use, Less Resource and Lower Cost

34. The Steel Mini-Mill
• Completely changed the complexion of the steel industry
• Uses locally arising scrap to supply a local market
• Capital reduced by an order of magnitude, operating costs are low
• Much lower logistics costs
• Batches can be smaller
• Investment is affordable
• Product is the same quality as virgin steel for sections, rod and bar
• Now 30% (400 million tonnes / year) of steel production
• Changed by the small upstart company not the incumbents
• Overall system cost is lower
What Else Can we Change Like This?

35. Drivers in Construction
• Increasing emphasis on the through life cost
• Increasing regulatory requirement for improved energy
performance and reduced waste
• PPP type contracts are for service delivery over time not capital
cost
• Drive the need for:
– Rapid build with good quality finishes
– Safety, cleanliness, low disturbance and low waste
– Flexible and adaptable buildings
– Low through life energy use
– Low end of life costs
An Opportunity for Change that we are Resisting

36. Energy Life Cycle for Offices
Extraction Manufacture Disposal, including
Re-use and Recycling
Construction
Use (and Refurbishment) Demolition
Building Energy Consumption is Higher in Use than in
Manufacture and Construction
Source: Amato PhD 1995

37. FOR SALFORD
(Temperate)
• Solar heating
• Natural Ventilation
• Artificial Heating
• Free Heating
• Insulation
• Daylight
Reference: Architecture and the Environment Bioclimatic Building Design, David Lloyd Jones, 1998

38. Housing Concepts
Source: Grimshaw and Partners for World Steel Organisation

39. Building Sustainable Features into New Buildings
• Engineering design that uses the principles
– Build sustainability in
• Plan the assembly before manufacture and erection
– E.g. Distribution sheds
• Use of off-site manufacture or pre-assembly of components
– Walls, Floors, Roofs
• Use of IT in design manufacture and assembly
– Basic design, Fluid dynamics, Virtual reality simulation
Following Virtual Example Brings Together Existing
Technology from Around the World

40. Sustainable Features in Buildings
Source: Grimshaw and Partners for International Iron and Steel Institute, 2004

41. Refurbishment and Reuse Opportunities
• Half the value of the European construction market is
refurbishment
• Buildings made from components or framed in steel lend
themselves to reuse
– Reuse whole frame
– Extend or refashion existing building
– Dismantle and reuse component parts
• Improve structure, e.g.
– Insulate
– Overclad
– Glazing
• Micro generation, e.g.
– Solar, wind
– Anaerobic digestion
– Grey water

42. Refurbishment and Reuse Example: Winterton House
Source: Corus, Late 1980s

43. Social Factors
• Related to lifestyle and perception
• Difficult to gain objective measures
• Make people feel good about their environment
• Elements such as:
– Physical appearance
– Function, form and operation
– Balance and quality of public and private spaces
– Ergonomics
– Security and safety
– Transport

44. Environmental Impact:
Examples of Sustainable Construction

45. Environmental Impact in Construction
1 2 3 4
5 6 7 8

46. Ashden Rwandan Prison Anaerobic Digestion Example
• Influx of people to a resource poor community,
• Burns all the fire wood, generates untreated
sewage,
• Prisoners built anaerobic digestion plant in the
gardens
– Exclude air from pit of sewage and natural bacteria
produce methane
• No need to denude fire wood
• No sewage problem
• By-product is digestate for use a fertilizer
True Sustainable Intervention: Eliminate 2 problems, Create solutions
and Educate people to use their skills to repeat the benefit
Source: Ashden Awards, AD Section

47. Resource Efficient Systems Integrate Technologies to
Reduce Consumption
GRID TOP UP WIND TURBINE
ELECTRICITY
IC ENGINE
GAS TOP
COOLING Community,
UP FUEL Town, Factory,
CELL Store,
HEAT
Home
VEHICLE Excess
FUEL Heat
INCINERATE Waste
GAS
GASIFY SORT
EXTRA WASTE
CLEAN
DIGEST
FERTILIZER, COMPOST WASTE GLASS & METAL

48. MAKING THE CHANGE SO A
SUSTAINABLE BUILT ENVIRONMENT
BECOMES PART OF OUR FUTURE

49. Big Challenges to Adopting Sustainable Principles
• Global drivers and trends in resource availability favour this approach
but we must:
– Look at engineering and built environment problems differently;
– Make sure policy makers, business leaders, engineers and construction
industry understand change is needed and is possible;
– Aspire to deliver the benefits;
– Work collaboratively across technical and social disciplinary boundaries;
– Create a favourable legislative and regulatory environment
– Take account of the value of finite resources in our economics;
– Make attractive, reliable and useable products and demonstrate there are
benefits.
There is a Large Opportunity for Economic, Social and Environmental
Benefit
We need to Change Our Behaviour and Do Something

50. What Could We do?
Create a ‘Low Carbon Resource Efficient Community’
Based on an integrated set of projects
that
Combine industrial, residential, agricultural and transport applications
to
Exploit the inherent strengths of the Communities and Regions
And
Deliver Economic Well Being
To do this we need to:
• Facilitate links between research, development and commercial interests to create
value through application development.
• Create a range of supply partnerships appropriate to end users to increase adoption.
• Build supply chain networks that develop the UK industry base.
• Utilise a range of funding sources.

51. An Case Study of an Innovation Challenge
Fossil Carbon Light Oxygen
Heat Production
Carbon
Fossil Fuel Dioxide Rapid Plant
Gas Production Unit Growth
Hydrogen
Oils
Plant Matter Food
Carbon
Extraction
Power Generation Pharmaceuticals
Dioxide
And Bio Processing
Water Neutraceuticals
Vehicles Nutrients
Alkane, Alkene
or Alkyne
Methane
Hydrogen
Depleted Plant
Sewage
Anaerobic Matter
Digestion Unit
Food Waste
Brewing ands
Distillery Waste Fertilizer
Source:
Entering the Ecological Age: The Engineer’s Role
Bio Diesel and
Bio Ethanol Waste Land CPI and Arup

52. Conclusions
• Design things that use little energy
• Make or build them as efficiently as possible, preferably with reuse in
mind
• Think about resource flows before you design
• Think about resource flows through communities and systems
• Think how wastes can be eliminated or used as fuels or feedstocks
• Drive collaborative interdisciplinary working
• Take action
REDUCE, REUSE, RECYCLE, RELATE

53. The Centre for Process
Innovation
www.uk-cpi.com
CPI receives funding from:
Copyright CPI 2011. All rights reserved