Refine
Has Fulltext
- yes (4)
Document Type
- Peer-Reviewed Article (4) (remove)
Language
- English (4)
Division
In material development processes, the question if a new alloy is more sustainable than the existing one becomes increasingly significant. Existing studies on metals and alloys show that their composition can make a difference regarding the environmental impact. In this case study, a recently developed air hardening forging steel is used to produce a U-bolt as an example component in automotive engineering. The production process is analyzed regarding the environmental performance and compared with the standard quench and tempering steels 42CrMo4 and 33MnCrB5-2. The analysis is based on results from applying the method of Life Cycle Assessment. First, the production process and the alterations on material, product, and process level are defined. The resulting process flows were quantified and attributed with the environmental impacts covering Carbon Footprint, Cumulative Energy Demand, and Material Footprint as they represent best the resource-, energy- and thus carbon-intensive steel industry. The results show that the development of the air hardening forging steel leads to a higher environmental impact compared to the reference alloys when the material level is considered. Otherwise, the new steel allows changes in manufacturing process, which is why an additional assessment on process level was conducted. It is seen that the air hardening forging steel has environmental savings as it enables skipping a heat treatment process. Superior material characteristics enable the application of lightweight design principles, which further increases the potential environmental savings. The present work shows that the question of the environmental impact does not end with analyzing the raw material only. Rather, the entire manufacturing process of a product must be considered. The case study also shows methodological questions regarding the specification of steel for alloying elements, processes in the metalworking industry and the data availability and quality in Life Cycle Assessment.
The steel industry is responsible for a quarter of all industrial greenhouse gas emissions. So far, the environmental savings are mainly due to steel recycling. Besides recycling, the circular economy offers strategies to increase material efficiency and thus decrease the primary raw material demand. However, the potentials remain unexploited because circular economy concepts with a higher degree of circularity are not considered. The presented case study of an industrial machining knife illustrates how the production process can be improved by implementing various circular strategies. The environmental performance is analyzed by calculating and comparing the carbon footprint, the cumulative energy demand and the material footprint, and the material efficiency indicator. The results show that the implementation of the three overarching strategies of the circular economy - narrowing, closing, and slowing - contributes to a significant increase in material efficiency. The implementation also has a positive effect on the overall environmental performance. The circular production processes require less energy and resources and cause fewer emissions. Auxiliary processes such as additional transport routes are relevant, as they can reduce or even overcompensate for savings. These processes must be adequately considered and designed.
The paper describes patterns of resource use related to German households' equipment. Using cluster analysis and material flow accounting, data on socio-demographic characteristics, and expenditures on fuel, electricity and household equipment allow for a differentiation of seven different household types. The corresponding resource use, expressed in Material Footprint per person and year, is calculated based on cradle-to-gate material flows of average household goods and the related household energy use. Our results show that patterns of resource use are mainly driven by the use of fuel and electricity and the ownership of cars. The quantified Material Footprints correlate to social status and are also linked to city size, age and household size. Affluent, established and/or younger families living in rural areas typically show the highest amounts of durables and expenditures on non-durables, thus exhibiting the highest use of natural resources.
The concept Material Input per Service Unit (MIPS) was developed 20 years ago as a measure for the overall natural resource use of products and services. The material intensity analysis is used to calculate the material footprint of any economic activities in production and consumption. Environmental assessment has developed extensive databases for life cycle inventories, which can additionally be adopted for material intensity analysis. Based on practical experience in measuring material footprints on the micro level, this paper presents the current state of research and methodology development: it shows the international discussions on the importance of accounting methodologies to measure progress in resource efficiency. The MIPS approach is presented and its micro level application for assessing value chains, supporting business management, and operationalizing sustainability strategies is discussed. Linkages to output-oriented Life Cycle Assessment as well as to Material Flow Analysis (MFA) at the macro level are pointed out. Finally we come to the conclusion that the MIPS approach provides relevant knowledge on resource and energy input at the micro level for fact-based decision-making in science, policy, business, and consumption.