LCA on a Bus Body Component Based on Biomaterials

Transcription

1 LCA on a Bus Body Component Based on Biomaterials Speaker: Meike Schmehl 3rd International Conference on Life Cycle Management 2007 August 27-29, Zurich

2 Contents Introduction to the project Life Cycle Assessment Results Summary and outlook - Chair of Production and Logistics - 1

3 Project Development and exemplary application of a body component based on renewable resources Substitution of a body component of a MAN-passenger bus made of glass fibre reinforced polyester resin Application of the usual production technique (SMCtechnology) - Chair of Production and Logistics - 2

4 Team Engineering Corporation for Agriculture and Environment (German abbr.: Iglu), Göttingen Faserinstitut Bremen (FIBRE) Biocomposites and More (B.A.M.), Ipsheim NAFGO, Neerstedt Braunschweiger Kunststofftechnik (BKT) Technical University Braunschweig/Inst. for Geoecology Financed by the Deutsche Bundesstiftung Umwelt (Projekt-N ) - Chair of Production and Logistics - 3

5 Basic Materials Fibre Experiments with different kind of fibres: Hemp, cotton, flax Bests results were achieved by the use of hemp. Polymer PTP : (Polymer material made of Triglycerides and Polycarbon acid anhydrides) resin component: plant oil hardener component: carboxylic acid, ethanol Petrochemical ingredients: Mass% PTP -SMC-Paste - Chair of Production and Logistics - 4

6 Technical Realisation Press-moulding procedure: Pressure =180 bar Temperature =135 C Pressing time =10 min Results: - Chair of Production and Logistics - 5

7 Results of the technical development Production of a homogenous component with a surface of high quality and best flame resistance Production with the series tooling of the company BKT, no procedural changes had to be done. The component succeeded the main points of the MAN norm. The on-road test was successful over a year at a passenger bus in use. - Chair of Production and Logistics - 6

8 Procedure of the LCA Goal and scope definition LCA framework LCA according to DIN EN ISO et seqq. Inventory analysis Interpretation Environmental impacts of the product about its entire life cycle Impact assessment Comparative balance between reference component (glass fibre reinforced polyester resin GF-UP) and new developed components (nature fibre reinforced PTP NFK) - Chair of Production and Logistics - 7

9 Reference component: Body component made of glass fibre reinforced polyester resin (GF-UP); mass: 3.6 kg Data sources: Industry data (B.A.M., BKT, NAFGO), agricultural institutions, databases for inventories (Ecoinvent, Umberto process library,...) Software-Tool: Umberto from ifu Hamburg - Chair of Production and Logistics - 8

10 System Boundaries: NFK-Bus Body Component - Chair of Production and Logistics - 9

11 System boundaries: Reference GF-UP-component - Chair of Production and Logistics - 10

12 Assumptions/excerpt: Co-products: mainly system expansion (alternative product supply and credit to the product system of the component) The reference to the cultivation of hemp was an annual actively vegetated fallow. Disposal: VW-SiCon process (dismantling, shreddering, separation of materials, substitution of oil in blast furnace) Variant NFK I NFK opt Description Hemp fibre-ptp -material system with flame retardants; mass was comparable to the GF-UP component Optimised use of material at the prepreg-production NFK light Light weight (reduction of the mass at 25%) - Chair of Production and Logistics - 11

13 Estimation of the environmental impacts Material- & Energy balance Input Output Substance 1 Substance 2... Substance n Substance a Substance b... Substance x Cumulated Energy Demand (CED) according to VDI-directive 4600 Impact assessment with the methodology Eco-indicator 99 Eco-indicator 99: Hierarchist perspective (H, A) Normalisation Weights Human Health 1.54 E Ecosystem Quality 5.13 E Resources 8.41 E Chair of Production and Logistics - 12

14 Results (1): Eco-indicator 99 Eco-indicator 99 pts 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 0,0-0,1 GF-UP NFK I NFK opt Fossil fuels Minerals Acidification/eutrophication Ecotoxic substances Ozone layer depletion Ionising radiation Climate change Respiratory effects Carcinogenic substances - Chair of Production and Logistics - 13

15 Results (2): Eco-indicator 99 Eco-indicator 99 pts 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 The components based on biomaterials had the lowest impacts referred to the Ecoindicator 99 (-50 to -68%). Above all, the categories fossil energy and climate change were dominant. Categories minerals, carcinogenic substances: production of flame retardant had significant shares. 0,0-0,1 GF-UP NFK I NFK opt - Chair of Production and Logistics - 14

16 Results (3): Dominance analysis NFK Opt. NFK I 3% 43% 47% 7% 2% 36% 56% 6% Natural fibre PTP-system Additives, packaging Production 0 0,2 0,4 0,6 0,8 Eco-Indicator 99 Points The production of the resin-hardener-system and additives had got strong environmental impacts. Low impacts due to the cultivation of fibre plants and their further processing - Chair of Production and Logistics - 15

17 Results (4): Saving of primary energy NFK light vs. GF-UP - Chair of Production and Logistics - 16

18 Results (5) The use phase of automotive components especially in the bus sector (high operating time) is very important. At an average performance of 650 tkm petrol about 512 MJ could be saved. - Chair of Production and Logistics - 17

19 Summary Significant less environmental effects especially in the categories energy resources and climate change More efficient material use and less environmental effects were expected for the serial production of the NFKcomponent. Suggestions Realisation of a light-weight-component Final analysis of the environmental effects caused by the serial production of the NFK-component (follow-up project) - Chair of Production and Logistics - 18

20 Future prospects Data Input Reference installations Technological, economic and ecological parameters Regional specific parameters Implemented technologies Availability of agricultural areas Demand and supply Acceptance Scenarios Mass flow optimisation model ARGUS Constraints Emission limits Capacity restrictions Logistics Data Output Consideration of technological changes Representation of the development of technologies considering their life-time and possibilities of scaleups. Estimation of costs on national, regional or installation level. Calculation of the Net Present Value of the expenditures in the considered planning horizon for a defined base year Calculation of estimated emissions - Chair of Production and Logistics - 19

21 Thank You for Your Attention! - Chair of Production and Logistics - 20