How to Develop LCI Database for Thai Industry: case study refinery products

Transcription

1 How to Develop LCI Database for Thai Industry: case study refinery products by Mr. Puttipong PATTANAKITTIPONG Engineer Focus Center on LCA and EcoProduct Development (FC eco-lca) LCA), National Metal and Materials Technology Center (MTEC), National Science and Technology Development Agency (NSTDA) 1

2 Contents Introduction: Life Cycle Assessment Life Cycle Inventory (LCI) Data LCI Database of Thai Industry 2

3 Product Life Cycle Thinking Life cycle thinking expands the traditional focus on manufacturing processes to incorporate various aspects associated with a product over its entire life cycle. The producer becomes responsible for the products from cradle to grave and has to develop products with improved performance in all phases of the product life cycle The life cycle of a product and closing the loop 3

4 Evaluation & Auditing Tools Road Map - ISO Management Systems Product-Oriented Support Tools Environmental Performance Evaluation (EPE) ISO guidelines Environmental Auditing (EA) general principles audit procedures qualification criteria for environmental auditors ISO (EMS) general guidelines on principles, systems & supporting techniques ISO (EMS) specification with guidance for use Life Cycle Assessment (LCA) general principles & practices life cycle inventory analysis life cycle impact assessment life cycle improvement assessment Environmental Labelling (EL) basic principles for all environmental labelling terms & definitions symbols testing & verification guiding principles, practices & criteria for certification programs Other standards writers Source: Thailand Environment Institute ISO/IEC Guide 64 environmental aspects of product standards 4

5 ISO14040 LCA Definition LCA is a technique for assessing the environmental aspects and potential impacts associated with a product, process or service by: compiling an inventory of relevant inputs and outputs of a system; evaluating the potential environmental impacts associated with those inputs and outputs; interpreting the results of the inventory and impact phases in relation to the objectives of the study. 5

6 ISO Life Cycle Assessment, Principles and framework น ยามและขอบเขต ของการศ กษา LCA Framework การว เคราะห บ ญช ข อม ล (Inventory Analysis) การประเม นผลกระทบ (Impact Assessment) การแปลความ หมายของผลล พธ (Interpretation) การประย กต โดยตรง การพ ฒนาและ ปร บปร งผล ตภ ณฑ การวางแผนกลย ทธ การก าหนดนโยบาย การตลาด อ นๆ 6

7 LCA can Assess potential environmental impacts, at both local and global scales Quantify environmental impacts associated with a product/service Identify the key life cycle stage Identify the most significant impacts Identify the main contributors Best available scientific-based tool in comparisons between products/alternatives in order to identify environmentally-preferred choice 7

8 Applications of LCA Voluntary Improvement EMS Economic & Social Administration Process improvement (ex. Recycle process) Env. administration (ex.support for recycle) Industry EcoDesign Eco-Products LCA Green purchasing Society Self assertion Comparative assertion Env. Education Lifestyle Review Marketing Env. Label Env. Report Consumption (Consumer s mind) 8 Source: Inaba, AIST, Japan

9 Basic Basic Concept of of LCA LCA and and General Procedures Setting Setting up up Scope Scope of of Research Research Life-Cycle Life-Cycle Stage Stage Identification Identification of of Unit Unit Process Process Material Transportation Parts Assembly Products Use, Repair Recycling Recycling and Reuse Raw Material Acquisition Transportation Disassembly Incineration Landfill Inventory Inventory Analysis Analysis Estimate Estimate the the environmental impact environmental impact of of the the product product life life cycle cycle CO 2 SO 2 NOx Impact on Air Total nitrogen Total phosphorous Heavy metals Impact on water Impact Impact Assessment Assessment Evaluate Evaluate the the impact impact on on the natural the natural environment environment Global warming Water pollution Eutrophication Health effects Acidification Results Results Interpretation Interpretation Identify significant environmental challenges Checking Data LCA LCA Examination Examination and and Utilization Utilization of of Results Results Compilation in Reports Critical Review 9 Source: Norihiro Itsubo

10 Life Cycle Inventory Manufacturing Use Disposal Materials Foreground Data Importance Mining Electricity Fuels Background Data Source: INABA, AIST 10

11 LCI Database in Thailand Federation of Thai Industry Ministry of Industry (Department of Industrial Works) National Metal and Materials Technology Center Thai Environment Institute Thailand Research Fund 11

12 Thailand National LCI Database Infrastructure Energy, Utilities and Transportation Coal Petroleum Electric power Transportation system Water supply (surface / ground) Recycle and Waste Management Recycle Landfill Anaerobic digestion Incineration Industrial materials Plastics (PS, PE, PP, etc.) Non-ferrous metals Ferrous metals Aluminum Fibers Synthetic rubber (SBR, BR) Paper Petrochemicals (7) Commodity chemicals NaOH H2SO4 HCl Cl2 Lime Na2CO3 Sulfur Basic Materials Agriculture Cassava Cotton Corn Natural rubber Vegetable oil livestock Animal feed Sugar cane rice Building and Construction materials Steel Gypsum Cement Glass Wood Tiles 12

13 Steering Committee Avg.data First stage 2006 Central LCI Database (MTEC) Technical Committee#1 Technical Committee#2 Avg.data Technical advices Input-Output data (actual, estimate, theory) WG1: Natural Gas PTIT WG2: Refinery Products WG3: Petrochemical Products Technical advices Second stage WG4: Ferrous/non -ferrous WG5: Transportation system Industrial Specific Institutions WG6: Construction materials WG7: Agriculture WG8: Basic chemicals WG9: Recycle & Waste management 13

14 Net Work System of LCI Database Data Input Org. Central Database User Input Correction Registration Pass Word Input Record LCA Data-Base Search Pass Word ID Data Receive Data trans. Internet Server Source: Nobuhiko Narita, Japan Environmental Management Association for Industry 14

15 PTIT Operation Procedure Natural gas Refinery products Petrochemical products AVERAGE DATA USERs FTI and Industrial Specific Institutions AVERAGE DATA Central Database (MTEC) AVERAGE DATA Member/partner Govermental sector Research Institute/ University Others Construction Mat. Basic chemicals Etc. Others Transportation Agricultural products Electricity Tap water 15

16 LCI Database Refinery Product 16

17 Data management com. A com. B com. C com. D PTIT Central database Develop questionnaire with MTEC Allocate confidential data base on product Feed average data to central database Verify the data Receive average data for each product Verify/Validate the data by cross check method Transform the average data to database format Distribute database via internet using XML file 17

18 Working Process Setting Up Scope Gate to Gate Template Preparation Data Gathering Data Analysis Verification Validation National Database 18

19 Working Process Setting Up Scope Gate to Gate Template Preparation Data Gathering Data Analysis Verification Validation National Database 19

20 Scope and Boundary Gate to Gate Input: Material, External Energy, External Utility Output: Product, Co-product, Pollution Period: Product list Diesel Gasoline Gasohol JET Kerosene LPG Fuel Oil 20

21 Scope of LCI Air emission Raw material External Fuel External Water External Electricity Product By Product Wastewater Solid Waste 21

22 Scope of LCI Air emission Raw material External Fuel External Water External Electricity Process Product By Product Wastewater Solid Waste 22

23 Life cycle inventory Data collection Literature information scientific papers, public reports, LCA reports electronic databases (part of LCA software) Questionnaire Calculations based on mass balances Measurements product-specific data 23

24 Flow Diagram of Refinery 24 Source: Petroleum Institute of Thailand

25 Air Emission Quantity Unit Overall Data CO 2 xxx kg NOx xxx kg SO 2 xxx kg Raw Material Quantity Unit Crude oil xxx kg MTBE xxx kg Ethanol xxx kg Chemical xxx kg Catalyst xxx kg... xxx TSP xxx kg CFC xxx kg CO xxx kg VOCs xxx kg Heavy Metal xxx kg Product Quantity Unit Diesel xxx kg Benzin 91 xxx kg Benzin 95 xxx kg JET xxx kg Kerosene xxx kg LPG xxx kg Asphalt xxx kg Sulfur xxx kg Utilities Quantity Unit Electricity (onsite) xxx MJ Electricity (outside) xxx MJ Steam xxx MJ Cooling water xxx m3 Potable water xxx m3 Air xxx m3 Refinery Solid Waste Quantity Unit Oil Sludge kg.. Water Emission Quantity Unit Steam xxx kg BOD xxx kg COD xxx kg Sulfide xxx kg Oil&Grease xxx kg SS xxx kg TDS xxx kg Total N xxx kg Total P xxx kg Heavy Metal xxx kg.. xxx 25

26 Example of Questionnaire F2 F3 F1 U_CDU Input Inventory Inputs Crude Distillation Unit F4 F5 E_CDU Code Detail Quantity Unit Note F1 Crude oil XXXXX 1000MT From unit xxxx F_CDU Chemical xxx XXXXX Ton -... Utilities Code Detail Quantity Unit Note U_CDU Electricity XXXXX 1000MWh - U_CDU Fuel XXXXX Ton - U_CDU Steam XXXXX

27 Example of Questionnaire Output Inventory Products Code Detail Quantity Unit Note F2 LPG XXXXX 1000MT - F3 TOP XXXXX 1000MT - F4 Naphtha XXXXX 1000MT - Water Emission Code Detail Quantity Unit Note EW Condensate XXXXX Ton - EW Wastewater XXXXX m 3-27

28 Example of Questionnaire Output Inventory (Conti) Air Emission Code Detail Quantity Unit Note EA_CDU NO2 XXXXX ppm - EA_CDU NOx XXXXX ppm - EA_CDU SO2 XXXXX ppm - EA_CDU CO XXXXX ppm - EA_CDU CO2 XXXXX ppm - EA_CDU TSP XXXXX ppm - EA_CDU Lead EA_CDU PM XXXXX ppm -. Solid waste Code Detail Quantity Unit Note ES_CDU

29 Working Process Setting Up Scope Gate to Gate Template Preparation Data Gathering Data Analysis Verification Validation National Database 29

30 Data Analysis Simplify process Check mass balance and energy balance Allocation by energy density for each product in each process if possible Average by production share 30

31 Simplify flow diagram HDT ISOM CCR Treatment Fuel Gas LPG MX Gasoline/ Gasohol CDU Treatment Kerosene HTU TCU BBU FCCU HMU HCU Treatment Diesel Gas Oil 31 Bitumen

32 Mass Balance Energy Balance Verifying 32

33 Allocation and Averaging Allocation: based on Energy Density Averaging: based on production share (Horizontal) 33

34 Allocation and System Boundary Expansion Allocation Upstream Process Units X% Production System X% Energy and Emissions Primary Products Downstream Applications System Boundary Expansion Y% Co-products Petroleum System: X = 60-70%, Y= 30-40% Upstream Process Units 100% Production System X% Energy and Emissions Primary Products Downstream Applications Y% Co-products Downstream Applications 34

35 Averaging: base on production share (Horizontal) A comp. A1 A2 A3 3 A1 A2 A3 A1 A2 A ave. B comp. B1 B2 B3 ave. B1 B2 B3 B1 B2 B 3 C comp. C1 C2 C3 C1 C2 C3 + C 3 ave. +ave. +ave. ave. Vertical method Horizontal method Hybrid Method 35

36 Acknowledgement Prof. Dr. Atsushi Inaba, Japan Mr. Fumio Tanaka, Japan Assoc. Prof. Dr. Thumrongrut Mungcharoen,MTEC Ms. Kirana Chomkumsri, MTEC Petroleum Institute of Thailand: PTIT 36

37 THANK YOU 37

38 Components of LCA Impact Assessment Goal Definition and Scoping Improvement Assessment Inventory Assessment 38

39 Advantages of LCA Realistic associated environmental impacts: resource depletion, ecological and human health Maximum possible impacts Product-oriented environmental performance assessment Best available scientific-based tool in comparisons between products/alternatives in order to identify environmentally-preferred choice 39

40 The Use of LCA by Industry 40