Eco-efficiency analysis of a. nanotechnology

Transcription

1 Industrial approaches to LCA- Eco-efficiency analysis of a plastic material improved by nanotechnology Dr. Andreas Kicherer, BASF Aktiengesellschaft Ludwigshafen, Germany

2 Sustainable development Sustainable Development Economy Ecology Society Eco-Efficiency- Analysis SEEbalance - Analysis* * being developed

3 What is an Eco-Efficiency Analysis Method for the comprehensive assessment of products and processes. Ecological and economic aspects are given equal weight in assessments. The products are analyzed from the angle of the end customer. (Future) scenarios and effects of various action options are presented. Eco-efficiency analysis is a standard tool in the BASF Group; more than 300 analyses have been carried out

4 High technology leads to better eco-efficiency The environmental and economic advantages of the Ultradur High Speed relative to the standard Ultradur are due to its modified rheological properties. The addition of specially developed polymer nano particles reduces the melt viscosity. As a result, the molding temperature and the injection and holding pressure decrease, leading to: up to 15-25% energy savings simplified mold design and construction significant material savings when designing thin wall parts better surface properties and less pieces out of specification up to 20-30% shorter cycle times

5 System Definition: Injection molding components customer benefit (CB) BASF standard BASF innovation Production of 1000 injection molding components Ultradur 4300 G6 Ultradur 4300 G6 High Speed

6 System Boundaries: Ultradur production use extraction and transportation of raw materials Butanediol Terephthalic acid PBT production Use electricity production and distribution Glas Fibre production Pigment production Formulation Injection molding disposal Recycling incineration

7 System Boundaries: Ultradur High Speed production use extraction and transportation of raw materials Butenediol Terephthalic acid PBT production Use Nanoparticle production electricity production and distribution Glas Fibre production Pigment production Formulation Injection molding disposal Recycling incineration

8 Business Example: Flow properties of Ultradur High Speed allow a new design with 5% material savings What are the advantages for the customer?

9 Eco-Efficiency Portfolio Combines Environmental Impact with Costs customer benefit: Production of 1000 injection molding components environmental impact (norm.). 0,7 1,0 High eco-efficiency Material savings lead to a lower environmental impact Ultradur standard High Speed Ultradur Low eco-efficiency 1,3 1,3 1,0 costs (norm.) 0,

10 The Ecological Fingerprint and Costs Allow an in-depths Analysis of Strength and Weaknesses energy use 1,00 customer benefit: Production of 1000 injection molding components area use material use 0,50 0,00 risk potential emissions toxicity potential Ultradur standard High Speed Ultradur Euro/CB recycling processing compounding Raw materials Ultradur standard High Speed Ultradur

11 Assessment Factors of the society 20% 20% Energy consumption Raw material consumption Air emission Air emissions Greenhouse 50% 50% 50% warming potential 10% Area requirement 20% Emissionen Emissions 20% 10% Toxicity potential Risk potential Water emissions 35% Wastes 15% Ozone depletion potential Photochemical ozone creation potential Acidification potential 20% 20% 10%

12 LCA Methods for Nanomaterials Eco-efficiency (LCA) Methodology already includes: Whole life cycle with service life and end-of-life considerations Emissions, Energy and resource consumption Environmental impact for the production of the (nano-)materials Additional aspects for nano materials Intrinsic toxicity potential for different nano particles Exposure scenarios in all life cycles stages

13 Evaluation of Toxicity Potential comparison of toxicity potentials Each substance is categorized according to its R-Phases including the pre-chain (assessment by 50 toxicologists) effective toxicity = potential * exposure Differentiation between closed and open systems and the vapour pressure Additional differentiation for nanomaterials according to their persistance in the body Differentiation for different life cycle steps

14 Exposition Calculation in the Toxicity Potential IV Calculation Amount of substance used * Substance Factor * System Factor * Vapor Pressure Factor * (Nano persistance factor) = Result Example: Use of 2 kg Pentanol (Xn, Factor 400, high vapor pressure) in an Partially closed system : 2 * 400 * 0.1 * 1 * (1..10) =

15 Data and Assumptions: Toxicity Potential standard Ultradur Ultradur High Speed kg/cb exposition ToxPoints kg/cb exposition ToxPointsweighting Raw materials and compounding PBT 59, , Glas fibre 17, , % Additives 3, electricity 98, , processing and gasoline electricity , gasoline % max. sum sum production sum processing and gasoline total sum ,

16 Consequences of the Eco-Efficiency Analysis Environmental Impact (normalized) low bring to market! Depending on the position of the analysed product, different strategic recommendations are given. 1,0 reduce costs! develop alternatives! reduce environmental impact! high high 1,0 costs (normalized) low

17 Ideas for a Path Forward Do not develop new methodology for nano materials. Adopt existing tools onto the special requirements of nano materials (esp. toxicity) Involve the experts, but keep it simple

18 The Eco-Efficiency Team: Our Homepage:

19 Appendix and Back-up

20 Example 2: Investment in new process equipment Eco-Efficiency Analysis Ultradur High Speed Input data Number of shifts 3 Investment in new process equipment Investment in new process equipment Ultradur standard High Speed Ultradur Product name and properties unit Ultradur B 4300 G6 Ultradur B4300G6 High Speed Time Cycle processing sec/piece Material use (total) g/piece Mould price Machine dimension tons High Speed Ultradur: same cycle-time 25% mold price reduction

21 Determining the toxicity potential the EC classifications according to the Hazardous Materials Regulations (R-phrases) are used to determine the toxicity potential If no R-value exists, the toxicity potential is ranked from 0-3 (no potential to high potential). Separate classifications for production, utilization and disposal are determined. From the standpoint of the final consumer the utilization phase is the most important one, so it is weighted at 70%. The production phase is weighted at 20% and disposal at 10%. These individual values are then combined to yield a toxicity potential value

22 Toxicity Evaluation differentiated according to different effects relative evaluation of the individual effects assessment by toxicologists: What is more serious: a teratogenic effect or a skin-irritant effect? How much more serious? expert survey!

23 Survey Estimate of the toxic potential (R-phrases) 26 chosen substances evaluation on a scale ranging from 0 to 1000 points The evaluation is subjective - the personal estimates are of interest BASF toxicologists toxicology students

24 Survey: Substances Involved aniline R20/21/ /23/24/25 soda R36 ethanol none caffeine R22 butyl nitrite R23/25 potassium fluoride R23/24/25 hydrogen cyanide gas R26 nicotine R25-27 calcium phosphide R28 mercury R23-33 phosphoric acid R34 acetic acid R35 methanol R23/24/25-39/23/24/25 methylene chloride R40 mineral wool R38-40 sodium hydrogen sulfate R41 cinnamic alcohol R43 citral R38-43 diazomethane R45 manganese sulfate R48/20/22 ethylene thiourea R61-22 chloroacetamide R ethyl hexanoic acid R63 pentabromodiphenyl ether R48/21/22-64 pentyl acetate R66 isopropanol R

25 Mean Values 1000 BASF students aniline soda ethanol pentyl acetate caffeine i-propanol cinnamic alcohol Na-H sulfate phosphoric acid acetic acid citral butyl nitrite potassium fluoride mineral wool 2-ehtylhexanoic acid manganese sulfate nicotine methylene chloride calcium phosphate chloroacetamide pentabromodiphenyl ether methanol ethylene thiourea mercury hydrogen cyanide gas diazomethane

26 1000 Grouping 750 Group 4 Group Group Group 1 Group 2 0 pentyl acetate ca ffe in e i-propanol cinnamic alcohol Na-H sulfate phosphoric acid acetic acid citral butyl nitrite potassium fluoride mineral wool 2-ethylhexanoic acid manganese sulfate nicotine methylene chloride calcium phosphide chloroacetamide pentabromodiphenyl ether methanol ethylene thiourea mercury hydrogen cyanide gas diazomethane

27 Group 1 weak effects chapped skin sleepiness irritant harmful to health R 22, 36, 38, 66, 67 mean 100 rank < 5 examples: pentyl acetate caffeine isopropanol

28 Group 2 corrosive sensitizing acute toxic chronically harmful to health R 34, 35, 41, 43 mean 300 rank < 10 examples: cinnamic alcohol sodium hydrogen sulfate phosphoric acid acetic acid citral

29 Evaluation System harmful to health irritant toxic corrosive, sensitizing irreversible damage, cumulative reproduction toxicity suspected very toxic severe irreversible damage an additional effect carcinogenic

30 Determination of Toxicity Potential example toxicity potential substance 1 R 26/27 : 750 points, highly toxic substance 3 R 20/22 : 400 points, harmful to health substance 2 R 35 : 300 points, irritant substance 1 R 26/ points pre-chain: 0 P total 750 P substance 2 R points pre-chain: 0 P total 300 P calculation use: 0.5 kg factor: 0.5*750 = 375 P use: 0.5 kg factor: 0.5*300 = 150 P use: 400 points substance 3 R 20/ points pre-chain: = 525 P total: = 925 P production: 925 points

31 Determination of Toxicity Potential o-nitrochlorobenzen 1. production R-value R-value R-vaue R-value rating o-nitrochlorobenzene 23/24/25 points 33 T 750 group 5 2. pre-chain nitric acid R 23/24/25: R 33: quantity in pre-chain pre-factor 0.41 x 449 sulfuric acid toxic if inhaled, swallowed or upon contact with the skin risk of cumulative effects quantity in pre-chain pre-factor 0.22 x 300 chlorobenzene quantity in pre-chain pre-factor 0.73 x = = = 3. final result = 5195 use production =

32 Exposition Calculation in the Toxicity Potential Not only the toxicity of a substance is important for the impact to human beings. Another important effect is the likelihood of the contact with the substance. The same substance has much less toxic effects in a system where nothing is getting out than in an open system. To assess different situations, in the evaluation of the use phase and in the recycling step, the system must be determined. Depending on the category, a calculation factor will be introduced: Category Factor Closed System Partially Closed System Open system

33 Exposition Calculation in the Toxicity Potential II Additionally the vapor pressure of a system influences the contact to people. High vapor pressures make a contact more likely than low vapor pressures Category Factor Vapor pressure low <1 mm Hg (133,3 Pa) Vapor pressure medium 1-3 mm Hg ( Pa) Vapor pressure high >3 mm Hg (400 Pa)

34 Exposition Calculation in the Toxicity Potential III To consider the specific behavior of nano-particulates (I.e. particulates from diesel cars), another rating logarithmic system was introduced: Category Factor Not persistent Absorbed and reactive Remain in body

35 Example 1: Customer wants to try out Ultradur High Speed substituting standard Ultradur using the existing process equipment, i.e. without any initial investments in the injection molding machinery What are the advantages for the customer?

36 Example 1: Use of existing process equipment Eco-Efficiency Portfolio customer benefit: Production of 1000 injection molding components Environmental Impact (normalized) 0,7 1,0 1,3 High Speed Ultradur shows better ecoefficiency! Ultradur standard High Speed Ultradur 1,3 1,0 0,7 Costs (normalized)

37 Example 1: Use of existing process equipment Ecological fingerprint and costs energy use 1,00 area use 0,50 emissions customer benefit: 0,00 Ultradur standard High Speed Ultradur Production of 1000 injection molding components material use risk potential 600 toxicity potential 500 Euro/CB recycling processing compounding Raw materials Ultradur standard High Speed Ultradur

38 Example 1: Use of existing process equipment Interpretation of the results The use of Ultradur High Speed offers the highest eco-efficiency for the Example 1, using existing process equipment Savings of up to 20% in the electricity consumption during injection molding lead to a lower environmental impact Energy consumption is also significantly lower during compounding Further ecological benefit is given by a lower off-specification (e.g. scrap) rate The hourly machine costs are significantly reduced thanks to the reduction in the time cycle per piece

39 Example 2: Customer invests in new, simpler and lowercost process equipment for a new component, thanks to the excellent flow properties Ultradur High Speed: Investment in new process equipment What are the advantages for the customer?

40 Example 2: Investment in new process equipment Eco-Efficiency Portfolio customer benefit: Production of 1000 injection molding components Environmental Impact (normalized) 0,7 1,0 1,3 Cost advantage becomes higher Ultradur standard High Speed Ultradur 1,3 1,0 0,7 Costs (normalized)

41 Example 2: Investment in new process equipment Ecological fingerprint and costs energy use 1,00 area use 0,50 emissions customer benefit: 0,00 Ultradur standard High Speed Ultradur Production of 1000 injection molding components material use risk potential toxicity potential Euro/CB recycling processing compounding Raw materials Ultradur standard High Speed Ultradur

42 Example 2: Investment in new process equipment Interpretation of the results In the case of Example 2, investment in new process equipment, the ecoefficiency advantage between standard Ultradur and Ultradur High Speed increases thanks to the savings in the mold costs This option has no environmental advantage compared to the use of existing equipment

43 What is an Eco-Efficiency Manager: the program An eco-efficiency Manager is a customized MS Excel based software program for eco-efficiency calculations. The user-interface is based on two sheets: Input data interface : Customer can input his own data and choose a design/investment scenario. Other data are derived and calculated automatically to determine the life cycle environmental impact and the costs. Output Interface: results are depicted in diagrams where details on all environmental indicators and costs can be seen

44 Eco-Efficiency Manager: Input data interface Eco-Efficiency Analysis Ultradur High Speed Input data Number of shifts 3 Use of existing processing equipment Choice of investment/design decission Ultradur standard Product name and properties unit Ultradur B 4300 G6 High Speed Ultradur Ultradur B4300G6 High Speed Specific user input data for the process Time Cycle processing sec/piece Material use (total) g/piece Mould price Machine dimension tons Corresponding High Speed values are calculated by the program

45 Eco-Efficiency Manager: Output interface portfolio fingerprint 0,7 Eco-Efficiency Portfolio Buttons: Choice of diagram energy material use GWP ODP AP waste area use water emissions POCP toxicity potential environmental impact (norm.). 1,0 Ultradur standard High Speed Ultradur risk potential costs 1,3 1,3 1,0 0,7 costs (norm.)

46 Eco-Efficiency Manager: Output interface portfolio fingerprint energy material use GWP ODP AP waste area use water emissions POCP toxicity potential risk potential costs