Material resources efficiency in engineering

Module M01: Introduction

Dr.-Ing. Felipe Cerdas

Institute for Machine Tools and Production Technology
Module structure - MRE
Today
Summary Introduction Kaya Identity and
Mitigation options
M1
M2
M13
Global Materials
M3 Flows
Mitigation Option VI:
Material substitution Economics, Society, Politics, Technology
M12
Environment
CO2, VOC, Nox, ... CO2, VOC, Nox, ... CO2, VOC, Nox, ... CO2, VOC, Nox, ...

Raw Material Manufacturing Product Use End of Life Ashby’s Sustainability

Production M4 Methodology
Mitigation Option V:
Consume less & M11
Longer Life products Refurbishment, Use of Components
Reuse
Recycling, Downcycling

Energy & Energy & Energy & Energy &

Water Water Water Water
Supply Supply Supply Supply
CO2, VOC, Nox, ... CO2, VOC, Nox, ... CO2, VOC, Nox, ... CO2, VOC, Nox, ... M5 Mitigation Option I:
Heat Potentials
16th of May (1/2)
Critical Resources & M10 Material flow Material flow (reverse) Energy / Water Information flow Emissions Product Life Cycle

Conflict Materials © IWF

M6
M9 23rd of May
Mitigation Option I:
M8 M7 Heat Potentials
Mitigation Option IV: (2/2)
Circular Economy Mitigation Option II:
Mitigation Option III: Light Weight Design
Reducing Yield Losses-
Additive Manufacturing Excursion week

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 2
Contents of today’s lecture module

M01 Introduction
▪ Educational objectives
▪ Sustainability
▪ Today's use of raw materials and the energy-carbon triangle
▪ Global CO2 emissions and the “Big 5”
▪ Looking at global dynamics
▪ IPAT identity
▪ What have we learned today?
▪ Related literature

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 3
Educational objectives M01
Introduction

Sustainability
▪ Definition of sustainable development and sustainability

Today’s use of raw materials and the energy-carbon triangle

▪ Overview of materials used in today's economies
▪ Energy resources and their contribution to total supply
▪ Embodied energy
▪ The materials-energy-carbon triangle
▪ Energy intensity and carbon intensity of materials

Global CO2 emissions and the “Big 5”

▪ Sources of annual industrial greenhouse gas (GHG) emissions

Looking at global dynamics

▪ Trends in manufacturing goods
▪ World population: historic and future growth
▪ Systems thinking

IPAT Identity

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 4
Contents of today’s lecture module

M01 Introduction
▪ Educational objectives
▪ Sustainability
▪ Today's use of raw materials and the energy-carbon triangle
▪ Global CO2 emissions and the “Big 5”
▪ Looking at global dynamics
▪ IPAT identity
▪ What have we learned today?
▪ Related literature

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 5
Sustainable Development vs. Sustainability
Sustainable Development Sustainability
Term Sustainability from the Brundtland Report:

„Sustainable development meets the needs of the present

without compromising the ability of future generations to meet
Earth’s Life Support
their own needs.“ System

People Planet Environment

Society
Economy

Sustainability
Society Environment

Sustainability Society
Economies

Economy

Sustainability
Profit

Weak definition Strong definition Rockström, J. (2015).

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 6
Contents of today’s lecture module

M01 Introduction
▪ Educational objectives
▪ Sustainability
▪ Today's use of raw materials and the energy-carbon triangle
▪ Global CO2 emissions and the “Big 5”
▪ Looking at global dynamics
▪ IPAT identity
▪ What have we learned today?
▪ Related literature

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 7
Annual production for selected materials used in today's production of
goods and supply of services

Annual production of
selected materials (weight)

→ Log scale

Ashby (2013), p. 19

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 8
The materials-energy-carbon nexus
First half

Materials

Energy intensity of
materials

Material intensity of
energy

Energy

Based on: Ashby (2013), p. 43

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 9
Utilized energy sources include fossil fuels, solar, lunar and nuclear – with
very different contribution share to total supply
Annual world energy
consumption by source

→ Log scale

Ashby (2013), p. 21

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 10
Energy Intensity of Materials
Embodied Energy

Embodied Energy

▪ The embodied energy of a material is the energy

that must be committed to create 1 kg of usable
material. Source: Ashby 2013. p. 121

▪ The energy is usually measured as the lower

heating value of the primary fuels used plus any
other primary energy contributions. Source: Gutowski et al. 2013

Based on: Ashby (2013), p. 43 Source: Ashby 2013. p. 150

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 11
The materials-energy-carbon nexus
First half

Materials

Energy intensity of
materials

Material intensity of
energy

Energy

Based on: Ashby (2013), p. 43

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 12
The materials-energy-carbon nexus
Full Picture

Materials

Energy intensity of Carbon intensity of

materials materials

Material intensity of Material intensity of

energy reduced carbon

Carbon intensity of
Energy energy
Carbon

Based on: Ashby (2013), p. 43

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 13
Energy Intensity of Materials and Carbon Intensity of Materials

Embodied Energy – CO2 Emissions

▪ There is a very strong correlation between

the carbon dioxide intensity and the energy
intensity of production

▪ The CO footprint of a material is the mass

2

of CO released into the atmosphere per

2

unit mass of material, units kg/kg.

Note: GHG emission figures refer to CO2 equivalent (global warming potential) for GHGs (e.g. carbon dioxide, methane, nitrous oxide) in 2005
Source: [Gutowski et al. 2013]

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 14
Contents of today’s lecture module

M01 Introduction
▪ Educational objectives
▪ Sustainability
▪ Today's use of raw materials and the energy-carbon triangle
▪ Global CO2 emissions and the “Big 5”
▪ Looking at global dynamics
▪ IPAT identity
▪ What have we learned today?
▪ Related literature

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 15
Sources of annual industrial greenhouse gas (GHG) emissions

Global anthropogenic GHG emissions Global energy/process GHG emissions

Buildings (elec
Agriculture,
Transport and heat)
Forestry & Land
21% 23%
Use (AFOLU)
19%
Energy /
Waste Global GHG process
3% emissions emissions
50 Gt 36.6 Gt
Industrial Industry
processes 38%
Energy
5% other
73%
18%

Data source: Our world in Data Sector by sector: where do global greenhouse gas emissions come from? - Our World in Data

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 16
 Technologies available to reduce CO2 emissions
Building and transport sector
Global energy/process GHG emissions

GHG emissions of an electrical car

CO2 emissions per
compared to a conventional car
Buildings (elec square meter buildings
Transport and heat)
21% 23%

Energy /
process
emissions
36.6 Gt
Industry
38%
other
18%

Allwood / Cullen (2012), p. 14

Bieker, G. (2021)

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 17
 Sources of annual industrial greenhouse gas (GHG) emissions

Global anthropogenic GHG emissions Global energy/process GHG emissions Global industrial GHG emissions

Agriculture, Buildings (elec

Forestry & Land Transport and heat)
Use (AFOLU) 21% 23%
19%
Energy /
Waste Global GHG process
3% emissions emissions
50 Gt 36.6 Gt Industry
Industrial 38%
processes
Energy
5%
73% other
18%

Production of five materials (steel, cement, paper, plastic and aluminum) account for 55% of
industrial emissions
Data source: Our world in Data Sector by sector: where do global greenhouse gas emissions come from? - Our World in Data Allwood / Cullen (2012), p. 13

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 18
Focus on most important materials

Based on: Gutowski et al. (2013)

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 19
Material production has a high relevance
Total energy breakdown (two examples)

Steel car door panel Aluminum beverage can

From: Allwood / Cullen (2012), p. 76

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 20
Contents of today’s lecture module

M01 Introduction
▪ Educational objectives
▪ Sustainability
▪ Today's use of raw materials and the energy-carbon triangle
▪ Global CO2 emissions and the “Big 5”
▪ Looking at global dynamics
▪ IPAT identity
▪ What have we learned today?
▪ Related literature

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 21
Looking at global dynamics

World Material Production Today

April 2023
Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction
Slide 22
Material production has been (exponentially) increasing in the past
Example of steel

World steel production

Graphic: Gutowski et al. (2013)

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 23
Trends in manufacturing growth

Cars and Built Space Steel, Cement and Paper

Gutowski, T. G., Allwood, J. M., Herrmann, C., & Sahni, S., (2013).

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 24
Historical growth of world population

Billion 7

Industrialization period
5

4 Today‘s world population:

8,03 billions [April 2023]
3
http://www.worldometers.info/world-population/
2

0
1 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
Year

▪ Growing world population

▪ Hyper-exponential growth rates in the last 200 years
Data from: U.S. Department of Commerce United States Census Bureau (2012)

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 25
World population growth scenarios
35

Billion
30

25

20 Constant-fertility
High
Medium
15
Low

10

-
1950 1960 1970 1980 1990 2000 2010 2020 2030 2040 2050 2060 2070 2080 2090 2100

Year
Data from: United Nations (2013)

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 26
Global dynamics requires systems-thinking
Reports to the Club of Rome
Report to the Club of Rome Example predictions made in 1972

Picture: Club of Rome

Graph: Meadows et al. (1972), from http://cassandralegacy.blogspot.de/2011/05/peak-oil-
thermodynamics-and-stoic.html (see also for more information)

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 27
Contents of today’s lecture module

M01 Introduction
▪ Educational objectives
▪ Sustainability
▪ Today's use of raw materials and the energy-carbon triangle
▪ Global CO2 emissions and the “Big 5”
▪ Looking at global dynamics
▪ IPAT identity
▪ What have we learned today?
▪ Related literature

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 28
IPAT-Identity

I = P  A  T

Impact Population Affluence Technology

(Environment)

Consumption Impact
Impact = Population  
Population Consumption

[Ehrlich & Holdren 1971; Commoner 1972, …]

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 29
IPAT-Identity
Consumption Impact
Impact = Population  
Population Consumption

7
Billion

0
1 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

[Gerland et al. 2014]

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 30
IPAT-Identity
Consumption Impact
Impact = Population  
Population Consumption

Gutowski, T. G., Allwood, J. M., Herrmann, C., & Sahni, S., (2013).

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 31
IPAT-Identity
Consumption Impact
Impact = Population  
Population Consumption

Source: [Gutowski et al. 2013]

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 32
IPAT-Identity
Consumption Impact
Impact = Population  
Population Consumption

Note: Industrial GHG emission figure refers to CO2 equivalent (global warming
[Allwood / Cullen 2012], Our World in data potential) for GHGs (e.g. carbon dioxide, methane, nitrous oxide) in 2005
Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction
Slide 33
IPAT-Identity
Consumption Impact
Impact = Population  
Population Consumption

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 34
Material efficiency
Definition and motivation

Definition
"Material efficiency [..] entails the pursuit of the technical strategies, business models, consumer
preferences and policy instruments that would lead to a substantial reduction in the production of
high-volume energy-intensive materials required to deliver human well-being."

Motivation
"The motivations for material efficiency include reducing energy demand, reducing the emissions
and other environmental impacts of industry, and increasing national resource security“

A closely related concept is material effectiveness or substitution: Using the right material
From: Allwood et al. (2013)

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 35
Material production, greenhouse gas reduction and (emerging) demand

If we aim to reduce our energy use by 50% (2050) to reduce carbon emissions ...

... and emerging economies catch-up with development towards developed economies, which
results in a doubling of demand for raw materials ...

... we need to reduce energy intensity of material production by 75% per material unit (kg).

Definition energy intensity

“The energy intensity (or embodied energy) is defined as the energy required to produce a
material from its raw form, per unit mass of material produced.”

Based on: Allwood / Cullen (2012), definition from Gutowski et al. (2013)

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 36
Uncertainty: Understanding of effects, evolvement of the future, information
availability

1. Cause-effect relations: How will today's actions affect the environment in the future?

2. Evolvement of the future: How will future (human) life evolve, and what impact will the future
state of the environment have on (human) life? How will (global) population evolve? What
materials will be needed, how will energy be generated?

3. Incomplete information: What are the specific current and future end-uses of materials?
What are (material) stocks available for extraction and recycling?

Based on: Allwood / Cullen (2012), pp. 19 ff.

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 37
Guiding Framework for the lecture
Sustainability Definition Global energy/process GHG emissions Materials-energy-carbon triangle

Carbon
Embodied Footprint
Energy

Big 5
Impact
Products

System
Thinking I = P  A  T
Impact Population Affluence Technology
(Environment)
World Population Growth
Manufacturing Trends Next Lecture Units
- What are the drivers for energy /
carbon intensity?
- Which strategies to reduce
energy / carbon intensity can be
applied?
- Where are the hotspots
- Which concrete measures exist
Global
or should be developed?
Dynamics

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 38
Contents of today’s lecture module

M01 Introduction
▪ Educational objectives
▪ Sustainability
▪ Today's use of raw materials and the energy-carbon triangle
▪ Global CO2 emissions and the “Big 5”
▪ Looking at global dynamics
▪ IPAT identity
▪ What have we learned today?
▪ Related literature

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 39
Educational objectives M01
Introduction

Sustainability
▪ Definition of sustainable development and sustainability

Today’s use of raw materials and the energy-carbon triangle

▪ Overview of materials used in today's economies
▪ Energy resources and their contribution to total supply
▪ Embodied energy
▪ The materials-energy-carbon triangle
▪ Energy intensity and carbon intensity of materials

Global CO2 emissions and the “Big 5”

▪ Sources of annual industrial greenhouse gas (GHG) emissions

Looking at global dynamics

▪ Trends in manufacturing goods
▪ World population: historic and future growth
▪ Systems thinking

IPAT Identity

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 40
What have we learned today?

Please answer the following questions and prepare additional questions you would
like to ask during the next session!

1. How would you define the terms sustainable development and sustainability?

2. Can you name three main sustainability strategies related to materials?

3. Which are the so-called “Big 5” materials? Why are these named “Big 5” in the context of
sustainability?

4. How would you explain the development of the different factors described in IPAT-Identity over
time ?

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 41
Contents of today’s lecture module

M01 Introduction
▪ Educational objectives
▪ Sustainability
▪ Today's use of raw materials and the energy-carbon triangle
▪ Global CO2 emissions and the “Big 5”
▪ Looking at global dynamics
▪ IPAT identity
▪ What have we learned today?
▪ Related literature

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 42
Want to know more?

Download Link Download Link

“ … a book devoted solely to the
environmental aspects of
materials and their selection,
„Materials, transformed from natural resources into the buildings, production, use and disposal […]. It
equipment, vehicles and goods that underpin our remarkable explores human dependence on
lifestyles, are made with amazing efficiency. But our growing materials and its environmental
demand is not sustainable, so this optimistic, entertaining and consequences and provides
richly informed book evaluates all the options … with both eyes perspective, background,
open.“ methods, and data for thinking
about and designing with
materials to minimize their
environmental impact.”

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 43
References
Allwood JM, Cullen J (2012): Sustainable Materials: With Both Eyes Open. Cambridge: UIT Cambridge

Allwood JM, Ashby MF, Gutowski TG, Worrell E (2011): Material efficiency: a white paper. Resources, Conservation and Recycling 55(3):362-381

Allwood JM, Ashby MF, Gutowski TG, Worrell E (2013): Material efficiency: providing material services with less material production. Philos Trans A Math Phys Eng Sci. 371(1986): 20120496.

Asbhy M, Vakhitova T (2014): Material Risk and Corporate Sustainability: a White Paper.

Ashby MF (2013): Materials and the Environment: eco-informed material choice. 2nd ed. Butterworth-Heinemann, Waltham, MA.

Ashby MF (2015): Materials and Sustainable Development. 1st Edition. Butterworth-Heinemann, Waltham, MA.

Bieker, G. (2021): A global comparison of the life-cycle greenhouse gas emissions of combustion engine and electric passenger cars. communications, 49(30), 847129-102.

Brundtland Report (1987): Our common future. The World Commission on Environment and Development.

Cleveland CJ, Ruth M (1998): Indicators of Dematerialization and the Materials Intensity of Use. Journal of industrial ecology 2(3):15-50.

Commoner B. (1972): The Environmental Cost of Economic Growth. Chemistry in Britain 8(2):52-6

Ehrlich PR, Holdren JP (1971): Impact of Population Growth. Science, Vol.171

Forsund (1974): On the Measurement of Productive Efficiency, in: The Swedish Journal of Economics 76(2):141-15

Gerland P, Raftery AE, Ševčíková H, Li N, Gu D, Spoorenberg T, Alkema L, Fosdick BK, Chunn J, Lalic N, Bay G, Buettner T, Heilig GK, Wilmoth J (2014). World population stabilization
unlikely this century. Science, 234-237.

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 44
References
Gutowski TG, Sahni S, Allwood JM, Ashby MF, Worrell E (2013): The energy required to produce materials: constraints on energy-intensity improvements, parameters of demand. Phil.
Trans. R. Soc. A 2013 371, 20120003.

Gutowski, T. G., Allwood, J. M., Herrmann, C., & Sahni, S. (2013). A Global Assessment of Manufacturing: Economic Development, Energy Use, Carbon Emissions, and the Potential for
Energy Efficiency and Materials Recycling. Annual Review of Environment and Resources, 38(1), 81–106. http://doi.org/10.1146/annurev-environ-041112-110510

Helmers, E., & Marx, P. (2012). Electric cars: technical characteristics and environmental impacts. Environmental Sciences Europe, 24(1), 14. http://doi.org/10.1186/2190-4715-24-14

Herrmann C (2010): Ganzheitliches Life Cycle Management. Springer, Heidelberg.

OECD (2001): Measuring Productivity - OECD Manual: Measurement of Aggregate and Industry-Level Productivity Growth, OECD, Paris, 2001.
[http://www.oecd.org/dataoecd/59/29/2352458.pdf]

Rockström, J. (2015). Bounding the Planetary Future : Why We Need a Great Transition. Great Transition Initiative, (April).

UNEP (2011): Decoupling natural resource use and environmental impacts from economic growth, A Report of the Working Group on Decoupling to the International Resource Panel.
Fischer-Kowalski, M., Swilling, M., von Weizsäcker, E.U., Ren, Y., Moriguchi, Y., Crane, W., Krausmann, F., Eisenmenger, N., Giljum, S., Hennicke, P., Romero Lankao, P., Siriban
Manalang, A., Sewerin, S.

U.S. Department of Commerce United States Census Bureau (2012): World Population. http://www.census.gov/population/international/data/worldpop/table_history.php
[http://perma.cc/0dRJf7couX4]

United Nations, Department of Economic and Social Affairs, Population Division, Population Estimates and projections Section (2013): World Population Prospects: The 2012
Revision. http://esa.un.org/unpd/wpp/unpp/panel_population.htm

Von Gronau N, Lindemann M (2010): Einführung ins Produktionsmanagement.

Dr.-Ing. Felipe Cerdas I Lecture MRE I M01: Introduction

Slide 45
Material resources efficiency in engineering
Module M01: Introduction

Dr.-Ing. Felipe Cerdas

Institute for Machine Tools and Production Technology