Life Cycle Assessment and Costing for Measuring Sustainability of Coatings

Transcription

1 Sustainable Coatings EC European Coatings Conference, June 2013 Düsseldorf 1 Life Cycle Assessment and Costing for Measuring Sustainability of Coatings Dr. Matthias Harsch, Julian Maruschke, Judith Schnaiter, Backnang, Germany

2 LCA and LCC for Measuring Sustainability Overview 2 Sustainability Introduction Challenges for Coatings Tools LCA and LCC Application of LCA and LCC Outlook

3 Sustainability Introduction Characteristic Development of unsustainable Processes 3 Intensity Time Excessive increase short maximum strong decrease

4 Sustainability Introduction Challenges for a sustainable Future 4 increasing dynamic climate change; energy consumption demographic change megatrends of sustainability scarce resources fresh water shortage *Dynaxity = Dynamics + Complexity; Source: megatrends of sustainability, Bundesministerium für Umwelt, Berlin, 2008 Knowledge management of increasing dynaxity* increasing complexity

5 Sustainability Introduction Viewing Angle 5 overall view view into details Both views are mandatory to evaluate sustainability

6 Sustainability Introduction Interaction between Technosphere, Ecosphere and Society 6 Technosphere technical development application of technologies scarcities of materials (?) Ecosphere evolution renewable resources non-renewable resources Society sustainability economy ecology social Tools required to analyze this permanently changing interaction

7 Sustainability Introduction Knowledge Management - Part of LCS Services 7 production sites worldwide technologies (state-of-the-art, innovations) work time model LCS life cycle models technology strengths, weak points, potentials economy ecology resources, emissions Understand (transparency) rearrange evaluate implement limits of profitability, cost drivers bench hmark

8 Sustainability Introduction Sustainability in the Coating Industry 8 Coatings are generally sustainable: long-term protection saves resources 1 By corrosion and decay arises in Germany an economic loss of 3.9% (Western Europe: %) of the gross domestic product per year, equivalent to 100 billion in 2012² Sustainability is the driving force for new developments³ reduction of energy consumption raw materials, which allow a low content of volatile gases (VOC) Future properties by sustainable use of products like easy-to-clean or scratch resistance³ Sources:1) Deutsches Lackinstitut. 2) Deutsches Lackinstitut Nachhaltigkeit par excellence. Lack im Gespräch o.j. (114): 1. 3) European Coatings, Show 2013.

9 LCA and LCC for Measuring Sustainability Overview 9 Sustainability Introduction Challenges for Coatings Tools LCA and LCC Application of LCA and LCC Outlook

10 10 Challenges for Coatings General Fullfilment of technical performance is required social performance ecology technical economy sustainability

11 Challenges for Coatings Life Cycle Perspective 11 Non and renew wable resources Binders Solvents Pigments Coating Applic- production ation Use Fillers Additives Cost, energy and material efficiency in each process step End of life

12 Challenges for Coatings Life Cycle Modelling (LCM) Build-up of Life Cycle into a parameterized Model 12 Results Results Results Results Results Results LCM enables to look forward or backward from each point of a life cycle

13 Challenges for Coatings Life Cycle Perspective Detail: Selection of Production Routes 13 Products Epoxy Epoxidharz resin Acrylic Acrylatharz resin Polyurethane Polyurethanharz resin Bisphenol A Glycidylmethacrylat Hydroxyethylmethacrylat Hydroxyethylacrylat Methylmethacrylat Methyldiethanol als Diamin Polyether als Polyol Polyester als Polyol Butylacrylat Isocyanate Phenol Aceton Styrol Ethylenglykol Epichlorhydrin Acetoncyanhydrin Dicarbonsäure Cumol Allylchlorid Calciumhydroxid Acrylsäure Butanol Chlor Benzol Pyrolysebenzin Ethylbenzol Ethylenoxid Ethylen Methacrylsäure Propylen Propylenoxid Acrolein Ammoniak Resources Steinsalz Sodium chloride Erdöl Crude oil Natural Erdgas Life cycle perspective helps to find best solution Xylol Methan CO Synthesegas

14 Challenges for Coatings Life Cycle Perspective Detail: Material Efficiency at Application 14 cleaning losses coat residue overspray, solids on skids 50 solids purchased coat coat for application used coat on product often < 5 solvents cleaning losses coat residue exhaust air spray booth exhaust air drying oven

15 Challenges for Coatings Investment and Development of Operating Costs 15 Example: medium-sized painting plant 60 Total costs in mill. EURO millions in 20 years 2 millions/a operating costs 4 millions investment Plant operation time in years Long plant operation time consider the life cycle costs potential

16 Challenges for Coatings 16 Procedure of Investment Decisions classical procedure functional specification document bid solicitation placing of an order plant construction start of production plant optimization plant conversion optimized procedure total investment functional specification document systematic technology selection overview of promising alternatives bid solicitation technology simulation optimized concept identification of strengths, weaknesses and potential placing of an order plant construction start of production plant optimization Comprehensive preparation for long term investments is profitable

17 LCA and LCC for Measuring Sustainability Overview 17 Sustainability Introduction Challenges for Coatings Tools LCA and LCC Application of LCA and LCC Outlook

18 Tools LCA and LCC Life Cycle Assessment (ISO Standards & 14044) 18 production resources preparation LCA framework goal/ scope definition inventory analysis impact assessment recycling Measuring ecological sustainability use emissions to environment renewable resources carbon cycle

19 Tools LCA and LCC Life Cycle Costing 19 PRODUCT Ressources Extraction Production Use material cost manufacturing cost total production cost life cycle cost Disposal/ Recycling dynamic static Life Cycle Costing different system boundaries Capital Budgeting static dynamic Total Cost of Ownership investment cost operation and maintenance cost abandonment cost Purchase Operation Measuring economical sustainability Abandonment CAPITAL GOODS

20 Tools LCA and LCC Primary Energy Demand and Material Costs Max Min 20 Costs Preis s in pro per kg Primary energy in MJ per kg 4 Exotic products can have even higher values. more than 700 MJ more than BM/ B/ HÄ H (PE) BM/ B/ HÄ H (Ko) (Co) Lösemittel Solvent (PE) Lösemittel Solvent (Ko) (Co) Pigmente (PE) Pigmente (Ko) (Co) Additive (PE) Additive (Co) (Ko) Füllstoffe Filler (PE) Füllstoffe Filler (Co) (Ko) B = Binder H = Hardener Co = Costs PE = Primary energy Economy and ecology provide similar messages

21 LCA and LCC for Measuring Sustainability Overview 21 Sustainability Introduction Challenges for Coatings Tools LCA and LCC Application of LCA and LCC Outlook

22 Application of LCA and LCC Definition of Coating Process (Starting Point) 22 Modeling of coating process over life cycle One layer coating process for plastic cabinets (pretreatment not shown) 2 shift production, h/a, location Berlin (climate data) Solvent borne topcoat (5 solids), layer thickness 40 µm, transfer efficiency (manual) Resources Material and energy supply Spray booth Flash off Oven Cooling zone Periphery (hall, conveyor, VOC abatement) Use (not investigated) End-of-life Emissions

23 Application of LCA and LCC Coating Process (Starting Point) LCA Coating Process 23 PE = Primary energy (cradle to gate), direct = direct energy input to specific process step

24 Application of LCA and LCC Normalization of Resources and Emissions 24 Yearly impacts EU 28 countries Impacts Life cycle of coating process Normalisation: Cv = (Impacts Life Cycle of materials) / (Yearly impacts EU 28 countries) Characteristic values (Cv) without unit for ADP, GWP, POCP, AP, EP to show relevancy of impact categories

25 Application of LCA and LCC Coating Process (Starting Point) Normalization of LCA Results 25 Normalization to EU referenz factors 4,0E-02 3,5E-02 3,0E-02 2,5E-02 2,0E-02 1,5E-02 1,0E-02 5,0E-03 0,0E+00 ADP GWP POCP AP EP ADP = abiotic resource depletion; GWP = green house warming potential (carbon footprint); POCP = photochemical oxidants creation potential ; AP = acidification potential; EP = eutrophication potential

26 Application of LCA and LCC Coating Process (Starting Point) LCC Coating Process 26

27 Application of LCA and LCC Coating Process (Starting Point) LCA and LCC Coating Process 27 Primary energy - life cycle GWP - life cycle POCP - life cycle Costs - life cycle

28 Application of LCA and LCC Coating process (starting point) LCA and LCC coating process (Step 1) 28 Primary energy - life cycle GWP - life cycle POCP - life cycle Costs - life cycle Step 1: implementation of VOC abatement (fullfilment of VOC directive)

29 Application of LCA and LCC Coating Process (Starting Point) LCA and LCC Coating Process (Step 2) 29 Primary energy - life cycle GWP - life cycle POCP - life cycle Costs - life cycle Step 2: implementation of water borne coating (fullfilment of VOC directive)

30 Application of LCA and LCC Coating Process (Starting Point) LCA and LCC Coating Process (Step 3) 30 Primary energy - life cycle GWP - life cycle POCP - life cycle Costs - life cycle Step 3: improvement of material and energy efficiency

31 Application of LCA and LCC Coating Process (Starting Point) LCA and LCC Coating Process (Step 4) 31 Step 4: transfer of research results from bmbf-project ENSIKOM high material efficiency by recycling of solids and solvents high energy efficiency (compact process + UV curing), no gas use

32 Application of LCA and LCC Coating Process (Starting Point) LCA and LCC Coating Process (Step 4) 32 Primary energy - life cycle GWP - life cycle POCP - life cycle Costs - life cycle Step 4: implementation of new developed coating process?

33 Application of LCA and LCC Life Cycle Optimization Potential - Estimation 33 boundary conditions: 2-shift production process savings: difference starting point to step tons crude oil equivalents per year 10.4 oil trucks á 26t net load per year 670 tons CO 2 equivalents per year 5.5 Mio. km at 120g CO 2 per km In addition: reduction of 61.2 tons of VOC emissions per year

34 LCA and LCC for Measuring Sustainability Overview 34 Sustainability Introduction Challenges for Coatings Tools LCA and LCC Application of LCA and LCC Outlook

35 Outlook 35 Sustainable development needs Appreciation for life and nature Awareness of interaction between technosphere and ecosphere under societal boundary conditions Different viewing angles, i.e. life cycle perspective versus view into details We have the consciousness and skills to create our future sustainable Let Us Do It

36 Contact Your contacts: Dr.-Ing. Matthias Harsch Managing director Dipl.-Ing. Julian Maruschke Project manager Dipl.-Ing. Judith Schnaiter Project manager