36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 1 INTRODUCTION ------------ 1.- THE MATERIALS CYCLE: INTRODUCTION 2.- ENVIRONMENTAL EFFECTS OF POLLUTION AND WASTE 2.1.- HEALTH EFFECTS IN HUMANS 2.2.- CLIMATE MODIFICATION 2.3.- EXAMPLE: LANDFILL AT LOVE CANAL 2.4.- EPILOGUE: IS THERE HOPE FOR SOLUTIONS? (LEAD PHASEDOWN) 3.- FINANCIAL IMPACT OF ENVIRONMENTAL REGULATIONS 3.1.- BRIEF REVIEW OF ENVIRONMENTAL REGULATIONS 3.2.- EXAMPLE: CLEANING UP MILITARY INDUSTRY TOXIC WASTES 3.3.- EXAMPLE: 1991 ALCOA WASTE FINES 3.4.- EPILOGUE: RISK ASSESSMENT 4.- WASTE 4.1.- DEFINITION AND CLASSIFICATION OF WASTE 4.2.- HAZARDOUS WASTE 5.- MANUFACTURING PROCESSES 5.1.- THE MANUFACTURING PROCESS AS A CONVERSION PROCESS 5.2.- CLASSIFICATION OF MANUFACTURING PROCESSES 6.- WASTE FROM MANUFACTURING 7.- HAZARDOUS WASTE PROCESSING AND DISPOSAL 7.1.- HAZARDOUS WASTE MANAGEMENT STRATEGIES 7.2.- HAZARDOUS WASTE TREATMENT METHODS 8.- TRANSFORMING TECHNOLOGY: TOWARDS CLEAN TECHNOLOGY READING ASSIGNMENT ------------------ * ARTICLE "TECHNOLOGY AND ENVIRONMENT: AN OVERVIEW" BY AUSUBEL ET AL., PP. 1-20, TEXT. * ARTICLE "DEMATERIALIZATION" BY HERMAN ET AL., PP. 50-69, TEXT. * ARTICLE "REGULARITIES IN TECHNOLOGICAL DEVELOPMENT" BY AUSUBEL, PP. 70-91, TEXT * EXECUTIVE SUMMARY OF "TRANSFORMING TECHNOLOGY" BY HEATON ET AL. * SUMMARY OF POLLUTION PREVENTION ACT OF 1990 HOMEWORK ASSIGNMENT ------------------- 1.- LIST SOME POLICY ALTERNATIVES LEADING TO A REDUCTION OF DEMAND ON THE EARTH'S RESOURCES. SELECT THE BEST ALTERNATIVE AND EXPLAIN YOUR CHOICE. 2.- ASUBEL (P. 72, TEXT) ARGUES THAT THE GROWTH OF TECHNOLOGICAL SYSTEMS CAN OFTEN BE REPRESENTED BY S-SHAPED CURVES. PROVIDE A QUALITATIVE EXPLANATION FOR THIS BEHAVIOR. 3.- DEFINE DEMATERIALIZATION. WHAT IS MORE LIKELY TO LEAD TO GREATER DEMATERIALIZATION: REDUCED WEIGHT OR INCREASED QUALITY OF THE INDUSTRIAL END PRODUCT? COMMENT AND GIVE ONE EXAMPLE. 4.- PROVIDE A QUALITATIVE EXPLANATION FOR THE OBSERVED DIFFERENCES BETWEEN THE PREDICTED AND ACTUAL CONSUMPTIONS OF FIVE METALS, SHOWN IN FIGURE 14, PAGE 85 OF YOUR TEXT. INTRODUCTION ------------ 1.- THE MATERIALS CYCLE * EARTH ---> RAW MATERIALS ---> PRIMARY (BASIC) MATERIALS ---> ENGINEERING MATERIALS ---> FINISHED PRODUCTS ---> CONSUMERS ---> WASTE * NOTE: WASTE IS PRODUCED IN ALL STAGES OF PROCESSING!!! 2.- ENVIRONMENTAL EFFECTS OF POLLUTION AND WASTE 2.1.- HEALTH EFFECTS IN HUMANS * HUMAN EXPOSURE PATHWAYS FOR WASTE (AIR, RUNOFF, LEACH) * AIR POLLUTION @ THE RESPIRATORY SYSTEM @ HEALTH THREATS POSED BY MAJOR AIR POLLUTANTS @ NATIONAL AMBIENT AIR QUALITY STANDARDS * WATER POLLUTION @ PRIMARY CAUSES OF WATERBORNE ILLNESS IN THE USA @ MAXIMUM CONTAMINANT LEVELS (VOC'S AND SECONDARY) 2.2.- CLIMATE MODIFICATION * POSSIBLE CAUSES FOR CLIMATIC CHANGE (EXTRATERRESTRIAL AND TERRESTRIAL) * POSSIBLE MECHANISMS FOR HUMAN-DRIVEN CLIMATIC CHANGE * GREENHOUSE EFFECT @ SCHEMATIC REPRESENTATION @ EVOLUTION OF MEAN TERRESTRIAL TEMPERATURE 1880-1990 @ HUMAN AND NON-HUMAN EFFECTS ON AIR POLLUTION @ N20 IN THE ATMOSPHERE (LONG TERM TREND) @ CH4 IN THE ATMOSPHERE (LONG TERM TREND) @ CO2 AND CH4 IN THE ATMOSPHERE (SHORT TERM TREND) @ SO2 IN THE ATMOSPHERE (SHORT TERM TREND) @ AIR TEMPERATURE VARIATIONS AND CO2 CONTENT @ LEAD AND SULPHATES IN GREENLAND'S ICE CAP * OZONE HOLES @ OZONE LAYER AS SCREEN OF UV RADIATION @ OZONE DISTRIBUTION IN THE ATMOSPHERE @ CFC PRODUCTION AND THE ANTARTIC OZONE HOLE * ACID RAIN @ THE HYDROLOGIC CYCLE (GLOBAL AND LOCAL VIEWS) @ MECHANISM FOR ACID RAIN DEPOSITION @ POSSIBLE REACTIONS INVOLVING AIR POLLUTANTS @ ACID RAIN ISOPLETHS FOR EASTERN USA @ PATHWAYS FOR ACID DEPOSITION THROUGH THE ECOSYSTEM 2.3.- EXAMPLE: LANDFILL AT LOVE CANAL * NIAGARA FALLS: ON THE NIAGARA RIVER BETWEEN LAKE ERIE AND LAKE ONTARIO * THE DEVEOPMENT OF HYDROELECTRIC POWER AND DIRECT CURRENT * THE DEVELOPMENT OF ENERGY INTENSIVE INDUSTRIES (LATE 1800'S) * W.T. LOVE PLAN FOR A CANAL TO JOIN UPPER AND LOWER LEVELS OF NIAGARA RIVER AND INTERRUPTION DUE TO DEVELOPMENT OF A.C. * INDUSTRIAL EXPANSION (ELECTROCHEMICAL, ABRASIVES, GRAPHITE, SODIUM HYDROXIDE, CHLORINATED ORGANIC CHEMICALS) * ENTER HOOKER CHEMICAL AND PLASTICS CORPORATION (1930'S) AND LANDFILLING ON THE NORTHERN QUARTER MILE SECTION OF LOVE'S CANAL. * LOVE CANAL AS A GENERALIZED CHEMICAL DUMP BY MID-1940'S. * LOVE CANAL CLOSED AND CAPPED BY HOOKER CHEMICAL IN 1952 * ENTER THE NIAGARA FALLS SCHOOL BOARD AND CITY COUNCIL AND THE NEED FOR A NEW ELEMENTARY SCHOOL, HOOKER ADVISE AGAINST IT AND FINAL SALE FOR $1 !!!! (1953). * SPORADIC INCIDENTS IN A GROWING COMMUNITY * SOME HORROR STORIES (MID-1970'S) * THE AFTERMATH @ AIR TOXICITY FINDINGS AND HEALTH PROBLEMS FINDINGS @ SOME CHEMICALS FOUND (E.G. BENZENE, CHLOROFORM, TRICHOLORO EHTYLENE, TRICHLOROPHENOL ...) @ ADMISION OF EXISTENCE OF A PROBLEM BY CITY (1977) @ EVACUATION OF 237 FAMILIES (1978) @ SOME PROPOSALS FOR SOLUTION @ EVACUATION OF 700 FAMILIES (1980) @ OUT-OF-COURT SETTLEMENT REACHED WITH 1345 RESIDENTS (MID- 1980'S) 2.4.- IS THERE HOPE? * LEAD USED IN GASOLINE AND LEAD IN HUMAN BLOOD * COSTS AND BENEFITS OF LEAD PHASEDOWN * COSTS AND BENEFITS OF AIR POLLUTION CONTROL ENVIRONMENTAL REGULATIONS ------------------------- 1.- RATIONALE FOR ENVIRONMENTAL LEGISLATION AND REGULATIONS * PRISIONER'S DILEMA * THE TRAGEDY OF THE COMMONS * CONCERNS RAISED ABOUT ENVIRONMENTAL REGULATIONS 2.- BRIEF REVIEW OF ENVIRONMENTAL REGULATIONS * LEGISLATIVE DATA SYSTEMS @ FEDERAL LEGAL INFORMATION THROUGH ELECTRONICS (FLITE) @ JUSTICE RETRIEVAL AND INQUIRY SYSTEM (JURIS) @ COMPUTER AIDED ENVIRONMENTAL LEGISLATIVE DATA SYSTEM (CELDS) @ LEXIS (U.S. CODE; FED. REGULS.; SUPR. & STATE COURT DECIS.) @ WESTLAW (AS LEXIS) * RIVERS AND HARBORS ACT OF 1899 * ATOMIC ENERGY ACT OF 1954 * NATIONAL ENVIRONMENTAL POLICY ACT OF 1970 @ COUNCIL ON ENVIRONMENTAL QUALITY @ ENVIRONMENTAL IMPACT STATEMENT (EIS) REQUIRED FOR ALL NEW PROJECTS PROPOSED BY FEDERAL AGENCIES * OCCUPATIONAL SAFETY AND HEALTH ACT OF 1970 @ PROTECTION OF HEALT AND SAFETY OF WORKERS IN THE WORKPLACE @ UPDATE RECORDS OF EXPOSED WORKERS REQUIRED * MARINE PROTECTION, RESEARCH, AND SANCTUARIES ACT OF 1972 @ TO CONTROL OCEAN DUMPING @ PERMITS REQUIRED * FEDERAL INSECTICIDE, FUNGICIDE, AND RODENTICIDE ACT OF 1972 ( AMENDED 1978) @ TO CONTROL STORAGE AND DISPOSAL OF PESTICIDES @ CLASSIFICATION: GENERAL USE, RESTRICTED USE, BANNED * CLEAN AIR ACT (1970, 1977, 1987) @ TO PROTECT AND ENHANCE THE QUALITY OF AIR @ PRIMARY AND SECONDARY AIR QUALITY STANDARDS SET @ CLASS I AREAS SET @ NONCOMPLIANCE PENALTY SET @ FEDERAL STANDARDS AND STATE STANDARDS * NOISE CONTROL ACT (1972-1978) * SAFE DRINKING WATER ACT (1974,1977) @ TO PROTECT THE SOURCES AND CONSUMERS OF DRINKING WATER @ PRIMARY AND SECONDARY WATER QUALITY STANDARDS SET @ FEDERAL AND STATE ROLES * FEDERAL WATER POLLUTANT CONTROL (CLEAR WATER) ACT (1972, 1977, 1981) @ TO RESTORE AND MAINTAIN INTEGRITY OF WATER @ CONTROL OF POLLUTANT DUMPING ONTO WATER @ ESTABLISH TREATMENT FACILITIES @ USE THE BEST AVAILABLE POLLUTION TREATMENT TECHNOLOGY @ EFFLUENT STANDARDS AND PERMIT (NPDES) SYSTEMS SET @ FEDERAL, STATE AND LOCAL RESPONSIBILITIES * TOXIC SUBSTANCES CONTROL ACT (1976) @ TO REGULATE INTRODUCTION OF NEW HAZARDOUS CHEMICALS @ DATABASE OF CHEMICAL CHARACTERISTICS REQUIRED * RESOURCE CONSERVATION AND RECOVERY ACT (RCRA) OF 1976 ---> HAZARDOUS AND SOLID WASTE AMENDMENT OF 1984 @ TO CONTROL SOLID WASTE DISPOSAL @ METICULOUS IDENTIFICATION AND TRACKING OF HAZARDOUS WASTE @ WASTE MANAGEMENT AND RESOURCE RECOVERY ENCOURAGED @ HAZARDOUS WASTE CLASSIFICATION AND EPA ID #'S @ STATE PROGRAMS AND EPA APPROVAL @ SMALL QUANTITY GENERATORS INCLUDED @ DISP0SAL RESTRICTIONS @ INSPECTIONS * COMPREHENSIVE ENVIRONMENTAL RESPONSE COMPENSATION AND LIABILITIES (CERCLA ) SUPERFUND ACT 1982-1990 ALSO SUPERFUND AMENDMENTS AND REAUTHORIZATION ACT (SARA) @ TO PROVIDE CLEANUP AND LIABILITY OF CONTAMINATED SITES @ SUPERFUND ESTABLISHED @ LIABILITY ESTABLISHED @ SITE INVENTORY REQUIRED @ EMERGENCY CLEANUP ACTIVITIES @ FEDERAL AND STATE ROLES @ EMERGENCY PLANNING AND COMMUNITY RIGHT-TO-KNOW @ MATERIAL SAFETY DATA SHEETS (MSDS) REQUIRED @ EMERGENCY AND HAZARDOUS CHEMICAL INVENTORY FORMS REQUIRED @ TOXIC CHEMICAL RELEASE REPORTING * POLLUTION PREVENTION ACT OF 1990 @ TO ESTABLISH NEW POLLUTION PREVENTION HIERARCHY @ BUILDS UPON PREVIOUS LEGISLATION * SUMMARY: FUTURE TRENDS IN ENVIRONMENTAL LAW @ NEW HIERARCHY OF PRIORITIES (EMPHASIS ON PREVENTION) @ INTEGRATED POLLUTION PREVENTION AND CONTROL 3.- EXAMPLES 3.1.- CLEANING UP MILITARY INDUSTRY TOXIC WASTES * MILITARY-INDUSTRY TOXIC WASTE CLEAN-UP PROJECT @ POLLUTERS: PENTAGON, DOE, NASA, .. @ MANY SITES INVOLVED @ 30 YEARS TO COMPLETE !!! @ COST ~ $ 400 BILLION !!! (1.5 INTERSTATE HGWY COST !!) @ SEE NYT, 8/5/91 * A-WEAPONS MANUFACTURING SITES @ COST ~ $100 BILLION !!! (NYT 9/6/91) 3.2.- 1991 ALCOA WASTE FINES * SITE AT MASSENA , NY * CHEMICALS: PCB, ACIDS, CAUSTICS ---> SOIL & GRASSE RIVER * WASTE FINES ~ $ 7.5 MILLION * CRIMINAL FINES ~ $ 3.75 MILLION * SEE, NYT 7/12/91 NOTE : POLLUTION CONTROL COSTS ARE ONLY LIKELY TO INCREASE ! 3.3.- EPILOGUE: RISK ASSESSMENT * FACTORS AFFECTING RISK ASSESSMENT OF WASTE * EVALUATION SCHEME FOR ASSESSING POTENTIAL HEALTH HAZARDS WASTE AND HAZARDOUS WASTE ------------------------- 1.- DEFINITION AND CLASSIFICATION OF WASTE * DEFINITION 1: "USELESS & WORTHLESS BYPRODUCT OF ACTIVITY" * DEFINITION 2: "A PRODUCT THAT ESCAPES WITHOUT BEING USED" * CLASSIFICATION 1: GAS, LIQUID, SOLID * CLASSIFICATION 2: NON-HAZARDOUS , HAZARDOUS * CLASSIFICATION 3: MUNICIPAL, URBAN, INDUSTRIAL * FLOWCHART FOR WASTE STREAMS 2.- HAZARDOUS WASTE (RCRA) * EPA CRITERIA TO DETERMINE IF A WASTE IS HAZARDOUS @ EXHIBITS H.W. CHARACTERISTICS (SEE BELOW), OR @ HAS BEEN LISTED AS H.W., OR @ IS A MIXTURE IN WHICH ONE COMPONENT IS A H.W., OR @ HAS NOT BEEN EXCLUDED FROM REGULATION AS A H.W. * HAZARDOUS WASTE (DEFINING CHARACTERISTICS: EPA CRITERIA) @ HAZARDOUS CHARACTERISTIC DEFINABLE IN TERMS OF PHYSICAL, CHEMICAL OR OTHER PROPERTIES @ DEFINING PROPERTIES MUST BE MEASURABLE BY STANDARIZED TESTING PROTOCOLS * HAZARDOUS WASTE (DEFINING CHARACTERISTICS) @ IGNITABILITY @ CORROSIVITY @ REACTIVITY @ EXTRACTION PROCESS TOXICITY * EPA-DESIGNATED HAZARDOUS WASTES @ NONSPECIFIC SOURCE WASTES @ SPECIFIC SOURCE WASTES @ COMMERCIAL CHEMICAL PRODUCTS 3.- WASTE FROM MANUFACTURING HAZARDOUS WASTE PROCESSING AND DISPOSAL --------------------------------------- 1.- HAZARDOUS WASTE MANAGEMENT STRATEGIES * EMPHASIS ON CONTROL AND TREATMENT * EMPHASIS ON PREVENTION AND TREATMENT 2.- HAZARDOUS WASTE TREATMENT METHODS * CHEMICAL TREATMENT @ SOLUBILITY @ NEUTRALIZATION @ PRECIPITATION @ COAGULATION AND FLOCCULATION @ OXIDATION AND REDUCTION @ DISINFECTION @ ION EXCHANGE @ INCINERATION * PHYSICAL TREATMENT @ SCREENING @ SEDIMENTATION @ CLARIFICATION @ CENTRIFUGATION @ FLOTATION @ FILTRATION @ SORPTION @ EVAPORATION AND DISTILLATION @ STRIPPING @ REVERSE OSMOSIS * BIOLOGICAL TREATMENT @ AEROBIC SYSTEMS @ ANAEROBIC SYSTEMS MANUFACTURING PROCESSES ----------------------- 1.- THE MANUFACTURING PROCESS AS A CONVERSION PROCESS * MANUFACTURING PROCESSES INPUTS, OUTPUTS, AND ACCUMULATION * CONVERSION EFFICIENCY 2.- CLASSIFICATION OF MANUFACTURING PROCESSES * CLASSIFICATION: METALS TECHNOLOGY VS NON-METALS TECHNOLOGY * METALS TECHNOLOGY @ SHAPING FROM THE MELT @ SHAPING FROM SOLID @ SHAPING FROM POWDER @ SHAPING FROM SOLUTION @ SHAPING BY MATERIALS REMOVAL @ SURFACE MODIFICATION * NON-METALS TECHNOLOGY @ CERAMICS PROCESSING (SYNTHESIS --> SHAPING --> FINISHING) @ POLYMER PROCESSING (SYNTHESIS --> SHAPING --> FINISHING) @ COMPOSITE MATERIALS PROCESSING 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 2 MANUFACTURING PROCESSES:INPUTS & OUTPUTS ---------------------------------------- 1.- INDUSTRIAL METABOLISM * NATURAL PROCESSES AND INDUSTRIAL PROCESSES AS MATERIALS TRANSFORMATION PROCESSES * COMMERCIAL MASS EXTRACTION OF ACTIVE MATERIALS (TABLE 1, AYRES) * CONSUMPTION RELATED MATERIAL EMISSIONS (TABLE 3, AYRES) * TECHNOLOGICAL AND BIOLOGICAL EVOLUTIONS 2.- THE PRODUCTION PROCESS 2.1.- ECONOMIST'S VIEW * INTRODUCTION * THEORY OF THE FIRM * ECONOMIC EXTERNALITIES 2.2.- ENGINEERING VIEW * MANUFACTURING PROCESSES * UNITS OF MEASUREMENT * PRINCIPLES USED IN MANUFACTURING POLLUTION ENGINEERING CALCULATIONS 2.3.- ANDERSON'S MODEL * SCHEMATIC VIEW OF THE PRODUCTION PROCESS @ FUNDS OF AGENT INPUTS (CAPITAL K ; LABOR L ) @ STOCK OF ENERGY INPUT ( E ) @ STOCKS OF MATERIAL INPUTS AND OUTPUTS (R ; Q AND W ) @ MASS AND ENERGY CONSTRAINTS ON THE PRODUCTION PROCESS @ IMPLICATIONS OF THE MODEL 3.- ENGINEERING MATERIALS BALANCE AND MATERIALS ACCOUNTING OF MANUFACTURING PROCESSES 3.1.- INTRODUCTION * SEQUENCE OF STEPS IN PERFORMING MATERIALS AND ENERGY BALANCES * DEPENDABILITY OF RESULTS 3.2.- PRINCIPLE OF MASS CONSERVATION * INPUT = OUTPUT + ACCUMULATION (GENERAL EXPRESSION) * INPUT = OUTPUT (STEADY STATE PROCESSES) 3.3.- ENGINEERING MATERIALS BALANCE (EMB) 3.4.- MATERIALS ACCOUNTING PROCEDURES (MA) 3.5.- EXAMPLES READING ASSIGNMENT ------------------ * ARTICLE "INDUSTRIAL METABOLISM" BY AYRES, PP. 70-91, TEXT * ARTICLE "DEMATERIALIZATION" BY HERMAN ET AL., PP. 50-69, TEXT (FINISH) * EXECUTIVE SUMMARY OF "TRACKING TOXIC SUBSTANCES AT INDUSTRIAL FACILITIES" BY COMMITTE TO EVALUATE MASS BALANCE INFORMATION FOR FACILITIES HANDLING TOXIC SUBSTANCES. * ARTICLE "THE PRODUCTION PROCESS: INPUTS AND WASTES" BY ANDERSON. HOMEWORK ASSIGNMENT ------------------- 1.- DERIVE AN EXPRESSION FOR THE THEORETICAL TECHNICAL RATE OF SUBSTITUTION FOR A PRODUCTION FUNCTION DESCRIBED BY A RESTRICTED COBB-DOUGLAS TECHNOLOGY. COMMENT ON YOUR RESULT. 2.- IS THERE ANY ADVANTAGE IN THE USE OF "UNIT OPERATIONS" FOR THE DESCRIPTION OF MANUFACTURING PROCESSES? EXPLAIN 3.- DESCRIBE THE DIFFERENCES BETWEEN THE ENGINEERING MATERIALS BALANCE APPROACH AND THE MATERIALS ACCOUNTING APPROACH WHEN TRACKING TOXIC SUBSTANCES IN INDUSTRY. COMPARE THE TWO APPROACHES. WHICH APPROACH IS BETTER? THE PRODUCTION PROCESS ---------------------- 1.- ECONOMIST'S VIEW * INTRODUCTION @ MICROECONOMICS @ ECONOMIC UNITS: FIRMS AND CONSUMERS @ ECONOMIC INTERACTION: MARKET INTERACTION @ OBJECTIVE, ACTIONS AND CONSTRAINTS @ SUPPLY AND DEMAND; EQUILIBRIUM AND DISEQUILIBRIUM * THEORY OF THE FIRM @ OBJECTIVE OF THE FIRM @ TECHNOLOGICAL CONSTRAINTS @ PRODUCTION PLAN AND PRODUCTION POSSIBILITIES SET @ OUTPUTS AND PRODUCTION FUNCTION @ INPUT REQUIREMENT SET @ ISOQUANTS @ EXAMPLES: LEONTIEFF TECHNOLOGY; COBB-DOUGLAS TECHNOLOGY @ TECHNICAL RATE OF SUBSTITUTION * ECONOMIC EXTERNALITIES 2.- ENGINEERING VIEW * MANUFACTURING PROCESSES @ INDUSTRIAL PROCESSES AS CONVERSION PROCESSES @ MANUFACTURING PROCESSES AS INDUSTRIAL PROCESSES @ MANUFACTURING ENGINEERING @ UNIT OPERATIONS OF MANUFACTURING ENGINEERING * UNITS OF MEASUREMENT * PRINCIPLES USED IN MANUFACTURING POLLUTION ENGINEERING CALCULATIONS @ THE LAW OF CONSERVATION OF MATTER @ THE LAW OF CONSERVATION OF ENERGY (1ST LAW OF THERMODYNAMICS) @ THE EQUILIBRIUM RELATIONSHIPS OF THE SYSTEM @ THE RATE RELATIONSHIPS OF THE SYSTEM @ THE LAW OF PRODUCTION OF ENTROPY (2ND LAW OF THERMODYNAMICS) 3.- ANDERSON'S MODEL * SCHEMATIC VIEW OF THE PRODUCTION PROCESS @ FUNDS OF AGENT INPUTS (CAPITAL K ; LABOR L ) @ STOCK OF ENERGY INPUT ( E ) @ STOCKS OF MATERIAL INPUTS AND OUTPUTS (R ; Q AND W ) @ MASS AND ENERGY CONSTRAINTS ON THE PRODUCTION PROCESS @ IMPLICATIONS OF THE MODEL ENGINEERING MATERIALS BALANCE AND MATERIALS ACCOUNTING OF --------------------------------------------------------- MANUFACTURING PROCESSES ----------------------- 1.- INTRODUCTION * SEQUENCE OF STEPS IN PERFORMING MATERIALS AND ENERGY BALANCES @ SKETCHING THE PROCESS BY A A FLOW SHEET @ SELECTION OF A BASIS OF COMPUTATION @ APPLICATION OF MATERIAL, ELEMENT, AND COMPONENT BALANCES @ IMPLEMENTATION OF ENERGY BALANCE @ APPLY EQUILIBRIUM RELATIONSHIPS @ APPLY RATE RELATIONSHIPS @ ITERATE * DEPENDABILITY OF RESULTS @ SAMPLING PROCESS STREAMS @ CHEMICAL AND PHYSICAL ANALYSIS OF SAMPLES @ ACCOUNTING FOR SURREPTITIOUS LOSSES 2.- PRINCIPLE OF MASS CONSERVATION * INPUT = OUTPUT + ACCUMULATION (GENERAL EXPRESSION) * INPUT = OUTPUT (STEADY STATE PROCESSES) 3.- ENGINEERING MATERIALS BALANCE (EMB) 4.- MATERIALS ACCOUNTING PROCEDURES (MA) 5.- EXAMPLES 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 3 CASTING PROCESSING ------------------ 1.- CASTING AS A MANUFACTURING PROCESS 1.1.- SOME FEATURES OF CAST METAL PRODUCTS 1.2.- INPUT REQUIREMENTS FOR THE PRODUCTION OF CASTINGS * ENERGY * MATERIAL 1.3.- SOME EXAMPLES OF CAST PRODUCTS 2.- MELTING PROCESSES 2.1.- THE MELTING PROCESS * ENERGY BALANCE * MELTING RATES 2.2.- METAL MELTING PROCESSES * INPUTS AND OUTPUTS * FUEL-BASED FURNACES * ELECTRIC FURNACES * OTHER FURNACES 3.- CASTING OPERATIONS 3.1.- THE CASTING SOLIDIFICATION PROCESS * FREEZING PHENOMENA * HEAT FLOW IN CASTINGS 3.2.- METAL CASTING PROCESSES * INPUTS AND OUTPUTS * SAND CASTING * INVESTMENT CASTING * OTHER PROCESSES 4.- CASTING INDUSTRY POLLUTION AND WASTE PROCESSING 4.1.- GAS TREATMENT 4.2.- OTHER DISCHARGES READING ASSIGNMENT ------------------ * ARTICLE "MEETING THE NEAR-TERM CHALLENGE FOR POWER PLANTS" BY BALZHISER, PP. 95-113, TEXT. * ARTICLE "ADVANCED FOSSIL FUEL SYSTEMS AND BEYOND" BY LEE, PP. 114-136 , TEXT (START) * ARTICLE "MINERALOGICAL CHARACTERISTICS OF ELECTRIC ARC FURNACE DUSTS" BY HAGNI ET AL. HOMEWORK ASSIGNMENT ------------------- 1.- ARE ELECTRIC FURNACE DUSTS HAZARDOUS WASTES? WHY? 2.- SUGGEST AT LEAST ONE PROCESS FOR THE MANAGEMENT AND CONTROL OF ELECTRIC FURNACE DUST. 3.- IDENTIFY THOSE MATERIAL STREAMS IN THE CASTING SHOP WHO NEED TO BE MONITORED BY A MATERIALS BALANCE OR A MATERIALS ACCOUNTING PROCEDURE IN ORDER TO TRACK DOWN HAZARDOUS CHEMICALS. 4.- IT IS WELL KNOWN THAT FINE PARTICLES IN DUST SETTLE DOWN BY GRAVITY AT A CONSTANT SPEED CALLED THE TERMINAL VELOCITY V . FURTHERMORE, V IS DIRECTLY PROPORTIONAL TO THE SQUARE OF THE PARTICLE RADIUS. WILL A SETTLING CHAMBER BE SUFFICIENT FOR THE CONTROL OF FOUNDRY DUST? EXPLAIN. IF NOT, WHAT WOULD YOU SUGGEST? 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 3 CASTING PROCESSING ------------------ 1.- CASTING AS A MANUFACTURING PROCESS 1.1.- SOME FEATURES OF CAST METAL PRODUCTS * CASTING AS A METAL SHAPING PROCESS * ADVANTAGES OF CASTING PROCESSING & COMPLEX SHAPES CAN BE PRODUCED & ALLOW ELIMINATION OF SUBSEQUENT OPERATIONS & UNIQUE FOR CAST-ONLY METALS AND ALLOYS & LEAD TO SIMPLER DESIGNS (DFM) & ADAPTS WELL TO MASS PRODUCTION & VERY LARGE CASTINGS CAN BE PRODUCED & SOMETIMES LEAD TO UNIQUE PROPERTIES & MANY ALLOYS CAN BE CAST & ECONOMIC ADVANTAGE (FROM THE ABOVE) 1.2.- INPUT REQUIREMENTS FOR THE PRODUCTION OF CASTINGS * ENERGY: TO MELT METAL AND TO OPERATE MACHINES & FROM CARBON BASED FUELS & FROM ELECTRIC POWER * MATERIAL & MAIN METAL AND ALLOYING ELEMENTS & FLUXING AND SLAGGING AGENTS & MOLD MATERIALS AND ADDITIVES 1.3.- SOME EXAMPLES OF CAST PRODUCTS * PUMP HOUSINGS, VALVES, HYDROELECTRIC PLANT PARTS, HEAVY MACHINERY PARTS ... (UP TO 200 TONS) * ARMATURE PARTS, COMMUTATOR RINGS, STATOR AND ROTOR PARTS, MOTOR FRAMES ... (ELECTRICAL INDUSTRY) * GEARS, PINIONS, WORMS (MECHANICAL INDUSTRY) * CONTINUOUSLY CAST PRODUCTS (STEEL AND NON-FERROUS) * TURBINE BLADES AND VANES, IMPELLER WHEELS * LIGHT METAL ALLOY PARTS (AIRCRAFT INDUSTRY) * BIOMEDICAL IMPLANT PARTS * SMALL COMPONENTS (DOWN TO GRAMS) 2.- MELTING PROCESSES 2.1.- THE MELTING PROCESS * ENERGY BALANCE & ENERGY REQUIREMENTS FOR MELTING & MINIMUM HEAT REQUIRED AND HEAT LOSSES & LATENT HEAT AND SENSIBLE HEAT & HEAT REQUIREMENTS OF SUBSIDIARY REACTIONS * MELTING RATES & HEAT TRANSFER MECHANISMS & HEAT TRANSFER RATES 2.2.- METAL MELTING PROCESSES * INPUTS AND OUTPUTS & ENERGY INPUTS & MATERIAL INPUTS: RAW METAL, FUEL MATERIALS, ADDITIVES & ENERGY OUTPUTS & MATERIAL OUTPUTS: MOLTEN METAL, EFFLUENT GAS/DUST, SLAG MAINTENANCE MATERIALS * FUEL-BASED FURNACES & BLAST FURNACE (PIG IRON) & CUPOLA FURNACE (CAST IRONS) & GAS FIRED FURNACES (LIGHT METAL ALLOYS) * ELECTRIC FURNACES & ELECTRIC ARC FURNACES & INDUCTION FURNACES * OTHER FURNACES & VACUUM MELTING & CONVERTERS (BOF) 3.- CASTING OPERATIONS 3.1.- THE CASTING SOLIDIFICATION PROCESS * FREEZING PHENOMENA & FREEZING = CHANGE FROM LIQUID TO SOLID & FREEZING = CHANGE FROM AMORPHOUS TO CRYSTALLINE & FREEZING = MICROSTRUCTURE FORMATION PROCESS * HEAT FLOW IN CASTINGS & HEAT EXTRACTION THROUGH THE MOLD WALL & HEAT EXTRACTION THROUGH THE MOLD/METAL INTERFACE & HEAT EXTRACTION THROUGH THE SOLIDIFIED SHELL & HEAT TRANSPORT IN THE LIQUID METAL 3.2.- METAL CASTING PROCESSES * INPUTS AND OUTPUTS & ENERGY INPUTS (NEGLIGIBLE, MAYBE MECHANICAL) & MATERIAL INPUTS: MOLTEN METAL, MOLD MATERIALS, ADDITIVES & ENERGY OUTPUTS: WASTE HEAT & MATERIAL OUTPUTS: CAST METAL, MOLD MATERIALS, EFFLUENT GAS/DUST, MAINTENANCE MATERIALS * SAND CASTING & STEPS IN THE PRODUCTION OF A SAND CASTING & COMPONENTS OF A SAND MOLD & MATERIALS FOR SAND CASTING MOLDS * INVESTMENT CASTING & STEPS IN THE PRODUCTION OF AN INVESTMENT CASTING & MATERIALS FOR INVESTMENT CASTING MOLDS * OTHER PROCESSES & RHEOCASTING & SPRAY CASTING 4.- CASTING INDUSTRY POLLUTION AND WASTE PROCESSING 4.1.- GAS TREATMENT * MATERIALS IN EFFLUENT GAS STREAMS & DUST, SMOKE AND FOG * GAS CLEANING & SETTLING CHAMBERS & CYCLONES & FILTERS & SCRUBBERS & ELECTROSTATIC PRECIPITATORS * OTHER TREATMENTS OF EFFLUENT GASES & SULFURIC ACID PRODUCTION ( SO2 > 5% ONLY) & LIMESTONE REACTION IN ABSORPTION TOWER & ABSORPTION WITH UPGRADING ( SODIUM CITRATE + TEMP ) 4.2.- SAND RECLAMATION * FLOW CHART * FLUIDIZED BED RECLAMATION 4.3.- SLAG PROCESSING 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 4 POWDER PROCESSING ----------------- 1.- POWDER METALLURGY PROCESSING 1.1.- SOME FEATURES OF POWDER METALLURGY PRODUCTS 1.2.- INPUTS AND OUTPUTS IN POWDER METALLURGY PROCESSING 1.3.- EXAMPLES OF POWDER METALLURGY PRODUCTS 2.- METAL POWDER FABRICATION PROCESSES 2.1.- MECHANICAL METHODS 2.2.- CHEMICAL METHODS 2.3.- ELECTROCHEMICAL METHODS 2.4.- METHODS BASED ON THE ATOMIZATION OF LIQUID METAL 2.5.- POWDER CHARACTERIZATION TECHNIQUES 2.6.- SAFE HANDLING OF METAL POWDERS 3.- POWDER CONSOLIDATION AND PRODUCTION OF FINISHED PRODUCTS 3.1.- PRODUCTION OF GREEN COMPACTS * CONVENTIONAL PROCESS * POWDER INJECTION MOLDING 3.2.- FURTHER TREATMENT OF GREEN COMPACT * SINTERING * WICKING OF PIM PRODUCT 3.3.- COMPACT CHARACTERIZATION 4.- POWDER METALLURGY INDUSTRY POLLUTION AND WASTE PROCESSING 4.1.- GAS TREATMENT 4.2.- OTHER DISCHARGES READING ASSIGNMENT ------------------ * ARTICLE "ADVANCED FOSSIL FUEL SYSTEMS AND BEYOND" BY LEE, PP. 114-136 , TEXT (FINISH) * ARTICLE "NO SCIENTIFIC CONSENSUS ON GREENHOUSE WARMING" BY SINGER * ARTICLE "TOXICITY OF METAL POWDERS" BY BELILES HOMEWORK ASSIGNMENT ------------------- 1.- IDENTIFY AND CLASSIFY ALL THE INPUT AND OUTPUT PROCESS STREAMS ASSOCIATED WITH THE GENERIC POWDER METALLURGY PROCESS. DISTINGUISH AMONG BYPRODUCT, ECONOMIC, ENERGY AND MAINTENANCE WASTES (SEE ANDERSON'S PAPER). 2.- RANK THE VARIOUS POWDER METALLURGY PLANTS ON THE BASIS OF THE TOXICITY OF SPECIFIC METALLIC MATERIALS BEING PRODUCED. (USE BELILES' ARTICLE) 3.- DISCUSS WHICH AREAS OF THE POWDER METALLURGY PLANT SHOULD BE SELECTED FIRST FOR THE IMPLEMENTATION OF A MATERIALS ACCOUNTING STRATEGY AIMED AT REDUCING POLLUTION AND/OR WASTE. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 4 POWDER PROCESSING ----------------- 1.- POWDER METALLURGY PROCESSING 1.1.- SOME FEATURES OF POWDER METALLURGY PRODUCTS * PM AS A METAL SHAPING PROCESS (FROM THE SOLID POWDER!) * REASONS FOR USE OF PM PRODUCTS & CAPTIVE: (REFRACTORY, REACTIVE) & ECONOMIC: (COST, PRECISION, PRODUCTIVITY) & UNIQUE: (ALLOY, MICROSTRUCTUR, COMPOSITES) 1.2.- INPUTS AND OUTPUTS IN POWDER METALLURGY PROCESSING * INPUTS & ENERGY: (POWDER PRODUCTION; POWDER CONSOLIDATION) & MATERIAL: (RAW MATERIAL, ADDITIVES) * OUTPUTS & FINISHED PRODUCTS & FLUE EXHAUST 1.3.- EXAMPLES OF POWDER METALLURGY PRODUCTS * ABRASIVES ----> PYROTECHNICS 2.- METAL POWDER FABRICATION PROCESSES 2.1.- MECHANICAL METHODS * GRINDING * MECHANICAL ALLOYING 2.2.- CHEMICAL METHODS * GASEOUS REDUCTION * THERMAL DECOMPOSITION * PRECIPITATION (FROM LIQUID OR FROM GAS) 2.3.- ELECTROCHEMICAL METHODS * CATHODIC PRECIPITATION FROM ELECTROLYTE 2.4.- METHODS BASED ON THE ATOMIZATION OF LIQUID METAL * LIQUID METAL ATOMIZATION (WITH GAS OR WITH WATER) * CENTRIFUGAL * MELT EXPLOSION 2.5.- POWDER CHARACTERIZATION TECHNIQUES * SAMPLING * POWDER SIZE AND SIZE DISTRIBUTION * POWDER PARTICLE SHAPE * SURFACE AREA OF A POWDER SAMPLE * POWDER FLOW PHENOMENA 2.6.- SAFE HANDLING OF METAL POWDERS * TOXICITY * FIRE HAZARD 3.- POWDER CONSOLIDATION AND PRODUCTION OF FINISHED PRODUCTS 3.1.- PRODUCTION OF GREEN COMPACTS * CONVENTIONAL PROCESS & ADDITIVES (LUBRICANTS, BINDERS) & POWDER COMPACTION METHODS * POWDER INJECTION MOLDING & ADDITIVES (BINDERS: THERMOPLASTIC POLYMER MATERIALS) 3.2.- FURTHER TREATMENT OF GREEN COMPACT * SINTERING & CONSOLIDATION DURING SINTERING VIA DIFFUSIONAL FLOW & STAGES OF THE SINTERING PROCESS (REACTIONS & CHANGES) & SINTERING FURNACES (NEED FOR ZONES) & SINTERING ATMOSPHERES * WICKING OF PIM PRODUCT (DEBINDING) & DEBINDING & SINTERING 3.3.- COMPACT CHARACTERIZATION 4.- POWDER METALLURGY INDUSTRY POLLUTION AND WASTE PROCESSING 4.1.- GAS TREATMENT 4.2.- OTHER DISCHARGES 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 5 METAL FORMING ------------- 1.- INTRODUCTION 1.1.- FEATURES OF PRODUCTS PRODUCED BY FORMING 1.2.- INPUT REQUIREMENTS FOR THE PRODUCTION FORMED PRODUCTS * ENERGY * MATERIAL 1.3.- SOME EXAMPLES OF FORMED PRODUCTS 2.- METAL FORMING PROCESSES 2.1.- INTRODUCTION * THE PLACE OF METAL FORMING IN THE MANUFACTURING HIERARCHY * RATIONAL FOR CHOSING FORMING OVER OTHER SHAPING PROCESSES 2.3.- DEFORMATION PROCESSING SYSTEMS * INPUTS AND OUTPUTS: MATERIAL AND ENERGY 2.4.- CLASSIFICATION OF METAL FORMING PROCESSES 2.5.- FORMING PROCESSES * BULK FORMING * SHEET FORMING 2.6.- FRICTION AND LUBRICATION IN METAL FORMING 3.- METAL FORMING LUBRICANTS 3.1.- SOLID SURFACES IN CONTACT UNDER PRESSURE 3.2.- FRICTION IN METALWORKING PROCESSES 3.3.- METALWORKING LUBRICATION SYSTEMS * LUBRICANT TYPES AND PROPERTIES * LUBRICANT BEHAVIOR DURING PROCESSING 3.4.- LUBRICANT TREATMENT METHODS READING ASSIGNMENT ------------------ * ARTICLE "HEALTH AND SAFETY ASPECTS OF LUBRICANTS" BY EYRES. * CHAPTER "FRICTION AND LUBRICATION IN METALWORKING" BY ROWE. HOMEWORK ASSIGNMENT ------------------- 1.- CONSTRUCT SCHEMATIC MATERIAL FLOW DIAGRAMS OF THE MOST IMPORTANT METAL FORMING PROCESSES. IDENTIFY THE VARIOUS INPUT AND OUTPUT PROCESS STREAMS AND SELECT PLACEMENT OF MONITORING STATIONS FOR THE IMPLEMENTATION OF A MATERIALS ACCOUNTING PROGRAM. 2.- SUGGEST AT LEAST ONE PROCESS FOR THE MANAGEMENT AND CONTROL OF HOT ROLLING MILL SCALE. 3.- CATALOG THE VARIOUS METALWORKING LUBRICANTS IN COMMON USE ON THE BASIS OF TOXICITY. SUGGEST TREATMENT METHODS AND/OR ALTERNATIVES FOR A PROCESS LUBRICANT OF YOUR CHOICE. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 5 METAL FORMING ------------- 1.- INTRODUCTION 1.1.- FEATURES OF PRODUCTS PRODUCED BY FORMING * METAL FORMING AS A SHAPING PROCESS * MICROSTRUCTURE OF WORKED MATERIAL 1.2.- INPUT REQUIREMENTS FOR THE PRODUCTION FORMED PRODUCTS * ENERGY & TO ANNEAL MATERIAL & TO DRIVE FORMING MACHINES * MATERIAL & RAW METAL STOCK & AUXILIARY MATERIALS (LUBRICANTS; SURFACE CLEANERS) 1.3.- SOME EXAMPLES OF FORMED PRODUCTS * FLAT PLATES, SHEET, FOIL, I-BEAMS, RODS * SOLID AND/OR HOLLOW BARS OF LARGE CROSS SECTION * ROD, WIRE * DISCRETE PARTS (CONNECTING RODS, CRANKSHAFTS, TOOLS) * FURNITURE, APPLIANCE BODIES, AIRCRAFT PANELS, CANS 2.- METAL FORMING PROCESSES 2.1.- INTRODUCTION * THE PLACE OF METAL FORMING IN THE MANUFACTURING HIERARCHY & EXTRACTION --> CASTING --> FORMING * RATIONAL FOR CHOSING FORMING OVER OTHER SHAPING PROCESSES & UNIQUE PROPERTIES; ECONOMIC; UNIQUE PROCESS 2.3.- DEFORMATION PROCESSING SYSTEMS * THE FOUR PROBLEM AREAS IN DEFORMATION PROCESSING & INCOMING MATERIAL PROPERTIES & INTERFACIAL CONTACT BETWEEN TOOL AND STOCK & PLASTIC DEFORMATION BEHAVIOR OF MATERIAL & RESULTING PROPERTIES OF OUTGOING PRODUCT * INPUTS AND OUTPUTS: MATERIAL AND ENERGY 2.4.- CLASSIFICATION OF METAL FORMING PROCESSES * BULK FORMING & COMPRESSIVE FORMING & COMBINED COMPRESSIVE/TENSILE FORMING * SHEET FORMING & TENSILE FORMING & BENDING & SHEARING 2.5.- FORMING PROCESSES * BULK FORMING & ROLLING & EXTRUSION & DRAWING * SHEET FORMING & BENDING & DEEP DRAWING & SHEARING & SPINNING, BULGING & NON-CONVENTIONAL METHODS 2.6.- FRICTION AND LUBRICATION IN METAL FORMING * STRUCTURE OF ENGINEERING METAL SURFACES * INTERACTION BETWEEN SOLID SURFACES IN CONTACT * IMPORTANCE OF FRICTION IN METAL FORMING & THERMAL CONDITIONS IN METAL FORMING & FRICTION COEFFICIENTS IN METAL FORMING 3.- METAL FORMING LUBRICANTS 3.1.- SOLID SURFACES IN CONTACT UNDER PRESSURE * WEAR PHENOMENA & ADHESION & ABRASION & MIXED MECHANISMS * LUBRICATION REGIMES & LUBRICANT FILM & MIXED & NO LUBRICANT 3.2.- FRICTION IN METALWORKING PROCESSES * METAL TRANSFER FROM WORKPIECE TO TOOLS * DESIRABILITY OF HIGH FRICTION IN SOME PROCESSES * THEORETICAL AND EXPERIMENTAL FRICTION COEFFICIENTS 3.3.- METALWORKING LUBRICATION SYSTEMS * ITEMS TO CONSIDER * SUMMARY OF LUBRICANTS USED IN METAL WORKING * LUBRICANT TYPES AND PROPERTIES & MINERAL OILS AND WAXES # ALIPHATIC (PARAFFINS [ALKANES, ALKENES]) # AROMATIC (ARENE; MIXED) & NATURAL OILS, FATS, AND DERIVATIVES, AND WAXES # FATTY OILS (SATURATED; UNSATURATED) # NATURAL WAXES (LANOLIN, BEESWAX) # FATTY OIL DERIVATIVES # SOAPS (METAL SALTS OF FATTY ACIDS) & SYNTHETIC FLUIDS # SYNTHETIC OILS (POLYBUTENE; CHLOROTRIFLUOROETHYLENE) # ESTERS (PRODUCTS OF ORGANIC ACIDS + ALCOHOL) # SILICON COMPOUNDS & COMPOUNDED LUBRICANTS # MINERAL OIL OR SYNTHETIC HYDROCARBON BASE # ADDITIVES $ BOUNDARY $ EXTREME PRESSURE (SULFONATED/CHLORINATED FATTY OILS) $ SOLID (C; MoS2) $ STABILIZERS & AQUEOUS LUBRICANTS (MOSTLY METAL CUTTING) # EMULSIONS (TINY DROPLETS OF OIL IN WATER) # SEMISYNTHETIC FLUIDS # SYNTHETIC FLUIDS (NO OIL) # TRUE SOLUTION # RELATED ISSUES: CORROSION; BIOLOGICAL CONTROL & COATINGS # METAL (TIN; ZINC; LEAD; COPPER) # POLYMERS # BONDED COATINGS # IN SITU (CVD; CHLORIDE FILMS BY ELECTROLYSIS) # FUSIBLE (OXIDES; SALTS) # GLASSY # CONVERSION (CONTROLLED SURFACE CORROSION; MULTILAYER) # PHOSPHATE (Zn; Cr; Na; K; OXALATE) * LUBRICANT BEHAVIOR DURING PROCESSING & LUBRICANT APPLICATION # SURFACE PREPARATION # TOTAL LOSS APPLICATION # MIXING OF LUBRICANT W/COOLING WATER & LUBRICANT STORAGE 3.4.- LUBRICANT TREATMENT METHODS * CHARACTERISTICS OF USED-UP LUBRICANT (DEBRIS; TRAMP OIL) * CLASSIFICATION OF TREATMENT SYSTEMS & BATCH SYSTEMS & FULL FLOW (RECYCLE) SYSTEMS & BYPASS SYSTEMS & COMBINED SYSTEMS (OPERATE EVEN WHEN WORKZONE IS OFF) * QUANTITIES ( 100 L/MIN - 20,000 L/MIN) * FLOW RATE ( 0.7 M/S) * CLEANING OF LUBRICANTS & SEPARATION BY DENSITY # SETTLING TANKS # FLOTATION # HYDROCYCLONE # CENTRIFUGE & FILTERING (COARSE SIEVES --> ULTRAFILTRATION) & ELECTRICAL/MAGNETIC * LUBRICANT REMOVAL (AQUEOUS; SOLVENTS [111-TCE];MECHANICAL) * LUBRICANT DISPOSAL & OIL RECLAMATION & TRAMP OIL REMOVAL --> EMULSION DESTABILIZATION # CHEMICAL # THERMAL # ELECTRICAL # FILTRATION (ULTRA) # MEMBRANE & OILY WASTEWATER # SAND BED FILTRATION # SETTLING TANKS # MECHANICAL FILTRATION # LANDFILL # ULTRAFILTRATION; REVERSE OSMOSIS # BIOLOGICAL PROCESSES READING ASSIGNMENT ------------------ * ARTICLE "HEALTH AND SAFETY ASPECTS OF LUBRICANTS" BY EYRES. * CHAPTER "FRICTION AND LUBRICATION IN METALWORKING" BY ROWE. HOMEWORK ASSIGNMENT ------------------- 1.- CONSTRUCT SCHEMATIC MATERIAL FLOW DIAGRAMS OF THE MOST IMPORTANT METAL FORMING PROCESSES. IDENTIFY THE VARIOUS INPUT AND OUTPUT PROCESS STREAMS AND SELECT PLACEMENT OF MONITORING STATIONS FOR THE IMPLEMENTATION OF A MATERIALS ACCOUNTING PROGRAM. 2.- SUGGEST AT LEAST ONE PROCESS FOR THE MANAGEMENT AND CONTROL OF HOT ROLLING MILL SCALE. 3.- CATALOG THE VARIOUS METALWORKING LUBRICANTS IN COMMON USE ON THE BASIS OF TOXICITY. SUGGEST TREATMENT METHODS AND/OR ALTERNATIVES FOR A PROCESS LUBRICANT OF YOUR CHOICE. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 6 METAL MACHINING --------------- 1.- INTRODUCTION 1.1.- MACHINING AS SHAPING BY MATERIAL ELIMINATION 1.2.- INPUT REQUIREMENTS FOR THE PRODUCTION OF MACHINED PRODUCTS * ENERGY: TO DRIVE MACHINES * MATERIAL: RAW STOCK; TOOL MATERIALS; AUXILIARIES 1.3.- SOME EXAMPLES OF MACHINED PRODUCTS 2.- METAL MACHINING PROCESSES 2.1.- CLASSIFICATION OF MACHINING PROCESSES * MECHANISTIC & MECHANICAL; THERMAL; ELECTRICAL; CHEMICAL * CHRONOLOGICAL & TRADITIONAL: CUTTING; GRINDING; MILLING; DRILLING ... & NON-TRADITIONAL: LASER AND EB; EDM; ECM; USM; WJM ... 2.3.- THE FUNDAMENTAL METAL CUTTING PROCESS * PHYSICAL PICTURE OF THE METAL CUTTING PROCESS & METAL DEFORMATION PHENOMENA & THERMAL PHENOMENA * ECONOMIC EFFECTS 3.- TOOL MATERIALS AND CUTTING FLUIDS 3.1.- TOOL MATERIALS * CLASSIFICATION & METALLIC: HSS; CAST ALLOYS & CEMENTED CARBIDES: Co-WC & SUPERABRASIVES: CERAMICS; SIALON; CBN, DIAMOND & GRINDING WHEELS: GRITS AND BONDS * ENVIRONMENTAL AND HEALTH ISSUES 3.2.- CUTTING FLUIDS * SEVERITY OF MACHINING OPERATIONS & CUTTING VELOCITY AND TOOL LIFE (TAYLOR'S EQN.) & CUTTING TEMPERATURE AND TOOL LIFE * FUNCTIONS OF CUTTING FLUIDS * CUTTING FLUID SELECTION * CLASSIFICATION OF CUTTING FLUIDS & WATER BASED FLUIDS & NEAT CUTTING OILS * ENVIRONMENTAL AND HEALTH ISSUES * CUTTING FLUID TREATMENT METHODS READING ASSIGNMENT ------------------ * ARTICLE "CUTTING FLUIDS IN INDUSTRY" BY BARTH. * CHAPTER 10 "COOLANTS AND LUBRICANTS" FROM BOOK ON METAL CUTTING BY TRENT. HOMEWORK ASSIGNMENT ------------------- 1.- CONSTRUCT SCHEMATIC MATERIAL FLOW DIAGRAMS FOR A METAL CUTTING AND A METAL GRINDING PROCESS.IDENTIFY THE VARIOUS INPUT AND OUTPUT PROCESS STREAMS AND SELECT PLACEMENT OF MONITORING STATIONS FOR THE IMPLEMENTATION OF A MATERIALS ACCOUNTING PROGRAM. 2.- LIST POTENTIAL SOURCES OF INFORMATION FOR A MATERIALS ACCOUNTING OF TOXIC SUBSTANCES IN THE MACHINE SHOP. 3.- CATALOG THE VARIOUS METAL CUTTING FLUIDS IN COMMON USE ON THE BASIS OF TOXICITY. SUGGEST TREATMENT METHODS AND/OR ALTERNATIVES FOR A PROCESS FLUID OF YOUR CHOICE. 4.- SUGGEST POSSIBLE TREATMENT PROCESSES FOR WORN CUTTING TOOL INSERTS. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 7 HEAT TREATING ------------- 1.- INTRODUCTION 1.1.- PHYSICAL PICTURE OF THE HEAT TREATING PROCESS 1.2.- HEAT TREATING AS A MATERIAL PROPERTY MODIFICATION PROCESS 1.3.- EXAMPLES OF HEAT TREATED MATERIALS 2.- HEAT TREATING PROCESSES 2.1.- INPUTS AND OUTPUTS 2.2.- EXAMPLES OF HEAT TREATING EQUIPMENT * CONTINUOUS PROCESSES * BATCH PROCESSES 2.3.- MATERIALS: METAL STOCK 2.4.- MATERIALS: ATMOSPHERES * EFFECT OF ATMOSPHERE ON METALS * PRINCIPAL ATMOSPHERES USED IN HEAT TREATING * ATMOSPHERE GENERATION AND CONTROL * SAFETY ISSUES 2.5.- MATERIALS: QUENCHING MEDIA READING ASSIGNMENT ------------------ * ARTICLE "ENERGY-EFFICIENT FURNACE DESIGN AND OPERATION" BY LAMPMAN. * ARTICLE "ENVIRONMENTAL ISSUES: IMPLICATIONS FOR ENGINEERING DESIGN AND EDUCATION" BY FRIEDLANDER, PP. 167-181, TEXT. * ARTICLE "WHERE DOES YOUR STATE RANK IN THE POLLUTION LINEUP?" BY HOLUSHA. HOMEWORK ASSIGNMENT ------------------- 1.- CONSTRUCT SCHEMATIC MATERIAL FLOW DIAGRAMS FOR A HEAT TREATING PROCESS.IDENTIFY THE VARIOUS INPUT AND OUTPUT STREAMS AND INDICATE POSSIBLE SOURCES OF INFORMATION YOU CAN USE FOR A MATERIALS ACCOUNTING OF THE PROCESS. 2.- LIST AND RANK SOME OF THE STRATEGIES THAT CAN BE USED TO IMPROVE THE ENERGY EFFICIENCY OF HEAT TREATING FURNACES. 3.- CATALOG THE VARIOUS GASES AND FLUIDS USED IN HEAT TREATING ON THE BASIS OF TOXICITY. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 7 HEAT TREATING ------------- 1.- INTRODUCTION 1.1.- PHYSICAL PICTURE OF THE HEAT TREATING PROCESS * HEAT TREATING AS A HEAT TRANSFER PROBLEM * KEY: CONTROL RATE OF HEATING, TIME AT TEMPERATURE AND RATE OF COOLING OF METAL PARTS 1.2.- HEAT TREATING AS A MATERIAL PROPERTY MODIFICATION PROCESS * PHASE CHANGES IN THE MATERIAL ARE INDUCED BY CONTROLLED HEATING AND COOLING * DIFFERENT PHASES IN THE MATERIAL POSSESS DIFFERENT PROPERTIES 1.3.- EXAMPLES OF HEAT TREATED MATERIALS * STEEL: TOOLS; GEARS * ALUMINUM: AIRCRAFT PARTS * SUPERALLOYS: TURBINE BLADES 2.- HEAT TREATING PROCESSES 2.1.- INPUTS AND OUTPUTS * INPUTS & ENERGY: TO HEAT FURNACES & MATERIAL: RAW STOCK; FURNACE ATMOSPHERE; QUENCHING MEDIA * OUTPUTS & ENERGY: FLUE LOSSES & MATERIAL: FLUE EXHAUST; SPENT QUENCHING MEDIA 2.2.- EXAMPLES OF HEAT TREATING EQUIPMENT * CONTINUOUS PROCESSES & HEAT TREATING OF STAINLESS STEEL AND BRASS STRIP AND WIRE & HARDENING-TEMPERING FURNACES (STEEL) * BATCH PROCESSES & RETORT FURNACES (STEEL CARBURIZING) & BELL FURNACES & SALT FURNACES & FLUIDIZED BED FURNACES & VACUUM FURNACES 2.3.- MATERIALS: METAL STOCK * STEELS * ALUMINUM ALLOYS * TITANIUM ALLOYS * NICKEL-BASE SUPERALLOYS * COBALT-BASE SUPERALLOYS * REFRACTORY ALLOYS 2.4.- MATERIALS: ATMOSPHERES * EFFECT OF ATMOSPHERE ON METALS & CHEMICAL REACTIONS BETWEEN METAL AND GAS & OXIDISING/REDUCING & CARBURIZING/DECARBURISING * PRINCIPAL ATMOSPHERES USED IN HEAT TREATING & EXOTHERMIC GAS (LEAN/RICH) (2-20% REDUCERS) & ENDOTHERMIC GAS (LEAN/RICH) (UP TO 60% REDUCERS) & MONOGAS (UP TO 95% N2 + 1% CO) & NITROGEN-HYDROGEN MIX (DISSOCIATED AMMONIA) & VACUUM * ATMOSPHERE GENERATION AND CONTROL * SAFETY ISSUES 2.5.- MATERIALS: QUENCHING MEDIA READING ASSIGNMENT ------------------ * ARTICLE "ENERGY-EFFICIENT FURNACE DESIGN AND OPERATION" BY LAMPMAN. * ARTICLE "ENVIRONMENTAL ISSUES: IMPLICATIONS FOR ENGINEERING DESIGN AND EDUCATION" BY FRIEDLANDER, PP. 167-181, TEXT. * ARTICLE "WHERE DOES YOUR STATE RANK IN THE POLLUTION LINEUP?" BY HOLUSHA. HOMEWORK ASSIGNMENT ------------------- 1.- CONSTRUCT SCHEMATIC MATERIAL FLOW DIAGRAMS FOR A HEAT TREATING PROCESS.IDENTIFY THE VARIOUS INPUT AND OUTPUT STREAMS AND INDICATE POSSIBLE SOURCES OF INFORMATION YOU CAN USE FOR A MATERIALS ACCOUNTING OF THE PROCESS. 2.- LIST AND RANK SOME OF THE STRATEGIES THAT CAN BE USED TO IMPROVE THE ENERGY EFFICIENCY OF HEAT TREATING FURNACES. 3.- CATALOG THE VARIOUS GASES AND FLUIDS USED IN HEAT TREATING ON THE BASIS OF TOXICITY. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 8 METAL JOINING ------------- 1.- INTRODUCTION 1.1.- METAL JOINING IN THE HIERARCHY OF MANUFACTURING PROCESSES 1.2.- ATTRIBUTES OF PRODUCTS PRODUCED BY JOINING 1.3.- METAL JOINING: INPUTS AND OUTPUTS 2.- METAL JOINING PROCESSES 2.1.- CLASSIFICATION OF METAL JOINING PROCESSES 2.2.- INPUTS AND OUTPUTS * INPUTS & ENERGY: TO PRODUCE DESIRED PROCESS TEMPERATURE & MATERIAL: WORKPIECE; FILLERS; ADDITIVES * OUTPUTS & MATERIAL: FINISHED PRODUCT; FUMES 2.3.- EXAMPLES READING ASSIGNMENT ------------------ * ARTICLE "ELIMINATE FUME PROBLEMS AT THE SOURCE", FROM THE WELDING JOURNAL, SEPT. 1991 HOMEWORK ASSIGNMENT ------------------- 1.- ARE WELDING FUMES TOXIC? WHY? ARE THEY HAZARDOUS WASTES? 2.- IDENTIFY POTENTIAL SOURCES OF INFORMATION THAT COULD BE USED FOR THE PREPARATION OF A MATERIALS ACCOUNTING PROCEDURE OF THE WELDING PROCESS 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 9 SURFACE PROCESSING ------------------ 1.- INTRODUCTION 1.1.- THE NEED FOR SURFACE PROCESSING 1.2.- SURFACE PROCESSING IN THE MANUFACTURING HIERARCHY 1.3.- INPUTS AND OUTPUTS IN SURFACE PROCESSING 1.4.- EFFECTS OF SURFACE PROCESSING 1.5.- EXAMPLES 2.- SURFACE MODIFICATION PROCESSES 2.1.- CLASSIFICATION OF SURFACE MODIFICATION PROCESSES * MATERIAL REMOVAL PROCESSES * MATERIAL ADDITION PROCESSES 2.2.- SURFACE MODIFICATION PROCESSES * INPUTS & ENERGY: TO OPERATE MACHINES & MATERIAL: WORKPIECE; CHEMICALS * OUTPUTS & MATERIAL: FINISHED PRODUCT; SPENT CHEMICALS 2.3.- EXAMPLES * MATERIAL REMOVAL PROCESSES & ALKALINE CLEANING & ELECTROLYTIC CLEANING & DEGREASING & ACID ETCHING (PICKLING) & ABRASIVE BLAST CLEANING & MECHANICAL FINISHING * MATERIAL ADDITION PROCESSES & ELECTROPLATING & NON-ELECTROPLATED METAL COATINGS & NON-METALLIC COATINGS READING ASSIGNMENT ------------------ * ARTICLE "SELECTION OF CLEANING PROCESS" FROM METAL HANDBOOK VOLUME 5. * ARTICLE "PRETREATMENT OF THE METAL SUBSTRATE BEFORE APPLICATION OF PLASMA SPRAYED CERAMIC COATINGS" BY KNIEWALD ET AL * ARTICLE "SAFETY AND PNEUMOCONIOSES: ABRASIVE BLASTING AND PROTECTIVE RESPIRATORY EQUIPMENT" BY LOGUE. * ARTICLE " THE RECYCLING OF HAZARDOUS METAL PLATING WASTES" BY ODLE ET AL. * DEVELOPMENTS IN COATINGS TECHNOLOGY: A MARKETING PERSPECTIVE" BY STERLING. HOMEWORK ASSIGNMENT ------------------- 1.- IDENTIFY POTENTIAL SOURCES OF INFORMATION FOR THE PREPARATION OF A MATERIALS ACCOUNTING OF THE VAPOR DEGREASING PROCESS 2.- SELECT MONITORING STATIONS FOR THE PREPARATION OF MATERIALS ACCOUNTING OF AN ABRASIVE BLAST CLEANING PROCESS 3.- COMPARE WASTE MINIMIZATION AND WASTE RECYCLING AS ELECTROPLATING WASTE MANAGEMENT STRATEGIES. DO YOU BELIEVE THAT STRIVING FOR WASTE MINIMIZATION COULD LEAD TO THE DOWNFALL OF RECYCLING EFFORTS? 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 10 CERAMIC AND GLASS PROCESSING ---------------------------- 1.- CERAMIC PROCESSING: INPUTS AND OUTPUTS 1.1.- INTRODUCTION 1.2.- MATERIALS * RAW MATERIALs * ADDITIVES * WASTES 1.3.- PROCESSES * POWDER PRODUCTION BY SPRAY DRYING * MILLING, SIZE CLASSIFICATION AND CONVEYING * MIXING * PRESSING; EXTRUSION; INJECTION MOLDING * SLURRY CASTING * FIBER PRODUCTION 2.- OTHER CERAMICS 2.1.- GLASS 2.2.- CEMENT READING ASSIGNMENT ------------------ * ARTICLE "ENERGY AND ENVIRONMENTAL CONSIDERATIONS FOR THE CEMENT INDUSTRY" BY TRESOUTHICK AND MISHULOVICH * ARTICLE "GLASS MANUFACTURING: STATUS, TRENDS AND PROCESS TECHNOLOGY DEVELOPMENT" BY RIDDERBUSCH * ARTICLE "THE RECOGNITION AND CONTROL OF OCCUPATIONAL DISEASE" BY LANDRIGAN AND BAKER. HOMEWORK ASSIGNMENT ------------------- 1.- IDENTIFY UNIT OPERATIONS OF CEMENT MANUFACTURE WHICH PRODUCE MOST OF THE POLLUTION AND WASTE. 2.- IDENTIFY UNIT OPERATIONS OF GLASS MANUFACTURE WHICH PRODUCE MOST OF THE POLLUTION AND WASTE. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 10 CERAMIC AND GLASS PROCESSING ---------------------------- 1.- INTRODUCTION 1.1.- CERAMIC MATERIALS * DEFINITION * CLASSIFICATION 1.2.- CERAMIC MATERIALS PROCESSING * PROCESS STEPS & POWDER PREPARATION & SHAPING AND FORMING & HIGH TEMPERATURE CONSOLIDATION & FINISHING * INPUTS AND OUTPUTS: ENERGY AND MATERIALS * TECHNICAL CERAMICS VS. CONVENTIONAL CERAMICS * EXAMPLES 2.- CERAMIC PROCESSING: INPUTS AND OUTPUTS 2.1.- MATERIALS * RAW MATERIALS & NATURALLY OCCURRING MATERIALS & INDUSTRIAL INORGANIC CHEMICALS & PARTICLE SIZE AND CHEMICAL COMPOSITION * ADDITIVES & LIQUID MEDIUM & SURFACTANTS & DEFLOCULANTS AND COAGULANTS & BINDERS & PLASTICIZERS & LUBRICANTS & FOAMING AGENTS & PRESERVATIVES * WASTES 2.2.- PROCESSES * POWDER PRODUCTION BY SPRAY DRYING * MILLING, SIZE CLASSIFICATION AND CONVEYING * MIXING * PRESSING; EXTRUSION; INJECTION MOLDING * SLURRY CASTING * FIBER PRODUCTION 3.- OTHER CERAMICS 3.1.- GLASS * INPUTS AND OUTPUTS: ENERGY AND MATERIAL 3.2.- CEMENT * INPUTS AND OUTPUTS: ENERGY AND MATERIAL READING ASSIGNMENT ------------------ * ARTICLE "ENERGY AND ENVIRONMENTAL CONSIDERATIONS FOR THE CEMENT INDUSTRY" BY TRESOUTHICK AND MISHULOVICH * ARTICLE "GLASS MANUFACTURING: STATUS, TRENDS AND PROCESS TECHNOLOGY DEVELOPMENT" BY RIDDERBUSCH * ARTICLE "THE RECOGNITION AND CONTROL OF OCCUPATIONAL DISEASE" BY LANDRIGAN AND BAKER. HOMEWORK ASSIGNMENT ------------------- 1.- IDENTIFY UNIT OPERATIONS OF CEMENT MANUFACTURE WHICH PRODUCE MOST OF THE POLLUTION AND WASTE. 2.- IDENTIFY UNIT OPERATIONS OF GLASS MANUFACTURE WHICH PRODUCE MOST OF THE POLLUTION AND WASTE. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 11 POLYMER PROCESSING ------------------ 1.- INTRODUCTION 1.1.- POLYMERS AS DERIVATIVES OF THE ORGANIC CHEMICALS INDUSTRY 1.2.- COMPARING POLYMERS WITH OTHER ENGINEERING MATERIALS 1.3.- TYPES OF PLASTICS 2.- POLYMER SYNTHESIS, CHARACTERISTICS AND PROCESSING 2.1.- POLYMER SYNTHESIS 2.2.- POLLUTION AND WASTE FROM SYNTHESIS 2.3.- POLYMER TYPES 2.5.- ADDITIVES FOR POLYMER PROCESSING 2.6.- POLYMER PROCESSING OPERATIONS READING ASSIGNMENT ------------------ * SECTION "PLASTIC AND RESIN WASTES" FROM BOOK BY NEMEROW & DASGUPTA PP. 567-575. * CHAPTER "POLYMERS AND THE ENVIRONMENT" FROM BOOK BY NICHOLSON, PP. 159-167 * ARTICLE "PROTECTING THE OZONE LAYER: A PERSPECTIVE FROM INDUSTRY" BY GLAS, PP. 137-155, TEXT * ARTICLE "THE RISE AND FALL OF ENVIRONMENTAL EXPERTISE" BY TSCHINKEL, PP. 159-166, TEXT 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 11 POLYMER PROCESSING ------------------ 1.- INTRODUCTION 1.1.- POLYMERS AS DERIVATIVES OF THE ORGANIC CHEMICALS INDUSTRY * THE ORIGIN OF POLYMERS (SEDIMENTARY GEOLOGICAL DEPOSITS FORMED 500 MY AGO BY ANAEROBIC DECAY OF MARINE ORGANISMS) * OIL TRAPS (ANTICLYNES; SYNCLYNES) * STABLE SPECIES FOUND IN OIL TRAPS & PARAFFINS (CHEMICALLY SATURATED HYDROCARBONS) & CYCLIC PARAFFINS (SATURATED RING MOLECULES) & AROMATICS (BENZENE DERIVATIVES) * EXPLOITATION & FOR USE AS FUEL (MAJORITY) & FOR CHEMICAL SYNTHESIS (SMALL AMOUNT) * SEPARATION & DISTILLATION & MATERIAL STREAMS RESULTING FROM CRACKING * THE ORGANIC CHEMICALS INDUSTRY 1.2.- COMPARING POLYMERS WITH OTHER ENGINEERING MATERIALS * BONDING * VISCOELASTICITY * OTHER POLYMER PROPERTIES 1.3.- TYPES OF PLASTICS 2.- POLYMER SYNTHESIS, CHARACTERISTICS AND PROCESSING 2.1.- POLYMER SYNTHESIS * MONOMER PRODUCTION VS. POLYMER PRODUCTION * PROCESSING OF C1,C2,C3,C4,C5 AND AROMATIC STREAMS * POLYMERIZATION & CONDENSATION (E.G. POLYESTER; POLYAMIDE; POLYURETHANE) & ADDITION (E.G. POLYETHYLENE; POLYVINYLCHLORIDE; POLYSTYRENE; POLYACRYLONITRILE; POLYMETHYLMETHACRYLATE) 2.2.- POLLUTION AND WASTE FROM SYNTHESIS * EXAMINATION OF SOME SYNTHESIS PROCESS FLOW DIAGRAMS & PVC & POLYSTYRENE & POLYMETHYLMETTHACRYLATE * COMPARING POLLUTION AND WASTE EMISSIONS OF ORGANIC CHEMICALS INDUSTRY WITH OTHER MANUFACTURING INDUSTRIES 2.3.- POLYMER TYPES * CLASSIFICATION & THERMOPLASTICS & THERMOSETTING & ELASTOMERS * MOLECULAR STRUCTURES & MOLECULE SIZE DISTRIBUTIONS & CRYSTALLINE/AMORPHOUS FRACTIONS & POLYMER BLENDS 2.5.- ADDITIVES FOR POLYMER PROCESSING * PLASTICIZERS AND EXTENDERS (E.G. ESTERS - DIBUTYL PHTALATE ; PHOSPHATES - TRIPHENYL PHOSPHATE; EPOXY DERIVATIVES ) * FILLERS (MOSTLY INORGANIC MATERIALS) * UV ABSORBERS - LIGHT STABILIZERS (BENZOPHENONES; BENZOTRIAZOLES; ACRYLIC ESTERS) * ANTIOXIDANTS (E.G. BUTYLATED HYDROXY TOLUENE; DYPHENYL AMINE) * HEAT (THERMAL) STABILIZERS (ORGANOMETALLICS: MERCAPTIDES OF SN, SB; STEARATES) * FLAME RETARDANTS ( ALUMINA TRIHYDRATE; HYDRATED MAGNESIUM SULFATE; ZINC BORATES) * ANTIMICROBIALS (ORGANOMETALLICS; ORGANIC SULFUR COMPOUNDS; QUATERNARY AMMONIUM COMPOUNDS) * COLORANTS (PIGMENTS AND DYES) * SURFACE-MODIFYING AGENTS & EXTERNAL LUBRICANTS (FATTY ACIDS; SOAPS) & MOLD-RELEASE AGENTS ( " ) & ANTIBLOCKING AND CLING AGENTS & ANTISTATIC AGENTS & ANTIFOGGING AGENTS 2.6.- POLYMER PROCESSING OPERATIONS * POLYMER PROCESSING AS A SHAPING OPERATION * MIXING * EXTRUSION PROCESSING * INJECTION MOLDING * FILM, SHEET AND FIBER PROCESSING * CALENDERING READING ASSIGNMENT ------------------ * SECTION "PLASTIC AND RESIN WASTES' FROM BOOK BY NEMEROW & DASGUPTA PP. 567-575. * CHAPTER "POLYMERS AND THE ENVIRONMENT" FROM BOOK BY NICHOLSON, PP. 159-167 * ARTICLE "PROTECTING THE OZONE LAYER: A PERSPECTIVE FROM INDUSTRY" BY GLAS, PP. 137-155, TEXT * ARTICLE "THE RISE AND FALL OF ENVIRONMENTAL EXPERTISE" BY TSCHINKEL, PP. 159-166, TEXT 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 12 COMPOSITE MATERIALS PROCESSING ------------------------------ 1.- INTRODUCTION 1.1.- COMPOSITE MATERIALS 1.2.- REINFORCEMENTS FOR COMPOSITES (FIBERS) 2.- COMPOSITE MATERIALS PROCESSING 2.1.- FIBER FABRICATION METHODS 2.2.- MATRICES FOR COMPOSITES 2.3.- COMPOSITE PROCESSING METHODS READING ASSIGNMENT ------------------ * ARTICLE "THE BENEFICIAL ENERGY AND ENVIRONMENTAL IMPACT OF COMPOSITE MATERIALS - AN UNEXPECTED BONUS" BY LEE ET AL. PP. 19-25. * ARTICLE "RECYCLING SMC SCRAP AS A REINFORCEMENT" BY JUTTE AND GRAHAM, PP. 13-15. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 12 COMPOSITE MATERIALS PROCESSING ------------------------------ 1.- INTRODUCTION 1.1.- COMPOSITE MATERIALS * DEFINITIONS * CLASSIFICATION * DESIGN CONSIDERATIONS 2.- COMPOSITE MATERIALS PROCESSING 2.1.- FIBER FABRICATION METHODS * GLASS * BORON * CARBON & PAN-BASED & PITCH-BASED * POLY-PARA-PHENYLENE-TEREPHTHAL-AMIDE (KEVLAR) * ALUMINA * ALUMINA + SILICA * SILICON CARBIDE * FIBER COMPARISON 2.2.- MATRICES FOR COMPOSITES * METALLIC * CERAMIC * POLYMERIC & THERMOSETTING # POLYESTER (A: FORMATION; B: CROSS-LINKING) # EPOXIES # POLYMIDES (CONDENSATION AND ADDITION) # PHENOLICS # CURING PROCESS & THERMOPLASTICS 2.3.- COMPOSITE PROCESSING * MANUAL LAY-UP * FILAMENT WINDING * SPRAY-UP METHODS * BAG MOLDING * SHEET MOLDING COMPUND MANUFACTURE * PULTRUSION * RESIN TRANSFER MOLDING * INFILTRATION PROCESSES & CVD & MELT & SLURRY * DIFFUSION BONDING READING ASSIGNMENT ------------------ * ARTICLE "THE BENEFICIAL ENERGY AND ENVIRONMENTAL IMPACT OF COMPOSITE MATERIALS - AN UNEXPECTED BONUS" BY LEE ET AL. PP. 19-25. * ARTICLE "RECYCLING SMC SCRAP AS A REINFORCEMENT" BY JUTTE AND GRAHAM, PP. 13-15. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 13 ELECTRONIC MATERIALS PROCESSING ------------------------------- 1.- ELECTRONIC MATERIALS 2.- PROCESSING: INPUTS AND OUTPUTS 2.1.- CRYSTAL GROWTH 2.2.- INTEGRATED CIRCUIT FABRICATION * PATTERNING & PHOTOLITHOGRAPHY & ETCHING * JUNCTION FORMATION & DIFFUSION & ION IMPLANTATION * DEPOSITION * METALLIZATION 2.3.- PACKAGING READING ASSIGNMENT ------------------ * ARTICLE "CHEMICAL HAZARDS IN THE SEMICONDUCTOR INDUSTRY", BY CHELTON ET AL., PP. 269-288 (HANDOUT). * ARTICLE "ENGINEERING OUR WAY OUT OF ENDLESS ENVIRONMENTAL CRISES" BY LYNN, PP. 182-191, TEXT. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 13 ELECTRONIC MATERIALS PROCESSING ------------------------------- 1.- ELECTRONIC MATERIALS * DEVELOPMENT OF INTEGRATED CIRCUITS * ELEMENTAL AND COMPOUND SEMICONDUCTORS & ELEMENTAL: Si AND Ge & COMPOUND: III-V; II-VI; IV-VI * Si AS PRINCIPAL SEMICONDUCTOR MATERIAL & METALLURGICAL GRADE Si & ELECTRONIC GRADE Si * ULTIMATE GOAL OF MICROELECTRONICS FABRICATION * PROCESS SUMMARY & CRYSTAL GROWTH & INTEGRATED CIRCUIT FABRICATION # PATTERNING # PHOTOLITHOGRAPHY # ETCHING & JUNCTION FORMATION # DIFFUSION # ION IMPLANTATION & DEPOSITION & METALLIZATION & PACKAGING 2.- PROCESSING: INPUTS AND OUTPUTS 2.1.- CRYSTAL GROWTH 2.2.- INTEGRATED CIRCUIT FABRICATION * PATTERNING & PHOTOLITHOGRAPHY & WAFER CLEANING & ETCHING (WET AND DRY) * JUNCTION FORMATION & DIFFUSION & ION IMPLANTATION * DEPOSITION & CHEMICAL VAPOR DEPOSITION & EPITAXY * METALLIZATION 2.3.- PACKAGING * LEVELS OF PACKAGING * CHIPS AND MODULES * MATERIALS FOR PACKAGING READING ASSIGNMENT ------------------ * ARTICLE "CHEMICAL HAZARDS IN THE SEMICONDUCTOR INDUSTRY", BY CHELTON ET AL., PP. 269-288 (HANDOUT). * ARTICLE "ENGINEERING OUR WAY OUT OF ENDLESS ENVIRONMENTAL CRISES" BY LYNN, PP. 182-191, TEXT. 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 14 OTHER PROCESSING INDUSTRIES --------------------------- 36696 POLLUTION AND WASTE FROM MANUFACTURING LECTURE # 15 EXAM # 2 ----------