IE 5390/IE4395 Special Topic: Environmentally Conscious (Benign) Manufacturing

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IE 5390/IE4395 Special Topic: Environmentally Conscious (Benign) Manufacturing Gabi v.

2 Table of Contents 1. Introduction Conducting the LCA 1.2 Goal & Scope Definition: ISO Goal & Scope Definition: Using GABI 2. Photocopier LCA The Final Model. 2.2 The Recycling Model 2.3 The Use Model 2.4 The Manufacturing Models 3. Life Cycle Impact Assessment Screening A Balance Result Mass Balance View Energy View 3.2 Dominance Analysis 3.3 Characterization, Normalization and Evaluation Characterization Normalization Evaluation 4. The GABI4 Analyst Parameter Variation. 4.2 Scenario Analysis 4.3 Monte Carlo Analysis 5. Categorization Allocation 60 Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 2

3 1. INTRODUCTION: You are a Manufacturing Engineering in-charge of conducting a LCA study about Photocopier super copy XR-2. You have a costumer who wants a photocopier but, he is concerned about the effects of the Photocopier on the environment. So you need to convince him that the photocopier is environmental friendly and show him how to dispose some of the components that are used in the photocopier. The name of the Product is Photocopier Supercopy. The results will not be published. Now narrowing down on what can be recycled or how to dispose some of the components are considered, 1. Disposable Toner 2. Disposable and recycling printed paper 3. Disposable Drum Now to economize the distance and the fuel consumed for traveling we consider all the disassembly unit, reassemble units and remanufacturing units are situated at a distance of 50km from each other. By using different principles of LCA you have to justify your model and show your model is friendly to the environment. The required assumptions can be made. There is nothing like a standard answer so try to give best justification of your results. All the design and analysis must be made in the GABI4 software Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 3

4 1.1 Conducting the LCA: Start First Goal and Scope (GaBi software) Calculating the balances (GaBi Software) Modeling the Product System Screening the balance results (GaBi Software) Data collection (GaBi Software) Dominance Analysis (GaBi Software) Modeling the System Photocopier Single Score Evaluation (GaBi Software) End Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 4

5 1.2 Goal and Scope Definition: ISO The Goal definition shall unambiguously state: 1. The intended application. 2. The reason for carrying out the study and 3. The intended audience. These goals statements shall be the basis for defining the questions to be addressed by the study The Scope of a LCA describes the model of the system to be studied. Linking the goal and scope definitions: The process of defining the scope of a study must always be directly related to the goal: The scope should be defined well enough to ensure that the breadth and depth of a study are compatible with and sufficient to address the stated goal. Scope definition is an iterative process (elements of the initially defined scope have to be reviewed and in practice often be revised). If the scope needs to be revised, ensure the definition is still directly linked to the goal. If not the goal definition must be revised. Elements of scope definition according to ISO: The function of the system(s); The functional unit; The system to be studied; The system boundaries; Cut-off criteria; The allocation procedures; The type of impact assessment; The methodology of impact assessment; Data requirements; Assumptions; Limitations; The initial data quality requirements; Type of critical review, if any and; The type and format of the report. 1.3 Goal & Scope Definition: Using GaBi Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 5

First, in the database manager, make a copy of your educational database CopierDB and name it SuperCopy XR-2. Then right click on your SuperCopy XR-2 database and select active from the menu.

6 First, in the database manager, make a copy of your educational database CopierDB and name it SuperCopy XR-2. Then right click on your SuperCopy XR-2 database and select active from the menu. Now, right click on your CopierDB and select disconnect. This will protect the integrity of your educational database. In the database manager, select new. This will open a blank window, similar to the one you see above. Here, enter the qualitative information about the study. If you leave this window minimized during your work on this project in this database, a record will be kept of the objects you use and create during the study. 2 LIFE CYCLE OF PHOTOCOPIER SUPERCOPY XR-2: Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 6

7 2.1 The Finial Model The processes involved in this plan are MANUFACTURING SUPERCOPY XR-2 UTILIZATION SUPERCOPY XR-2 END OF LIFE SUPERCOPY XR-2 DISPOSAL TONER DISPOSAL AND RECYCLING PRINTED PAPER DISPOSAL DRUM 2.2 The Recycling Models Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 7

8 Starting with No. 6 DISPOSAL DRUM To build the Disposal drum Recycling process plan we require: Drum (used) disassembly Diesel fuel Transport (long distance) Gas and Steam power plant Steel billet (electric furnace) Steel billet Waste incineration plant (municipal waste) Waste incineration plant (plastics) The required process and the flows can be dragged and dropped on to the plan. If any process or flow is missing then we have to create according to the data available. The figure below shows the details of a process that must created. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 8

Details of Drum (used) Copyright Tzu-Liang

In the database manager, in category waste for recovery, right click on the right side of the DB Manager to create a new unit process. Fill in the information as shown in the screen shot above.

10 In the database manager, in category waste for recovery, right click on the right side of the DB Manager to create a new unit process. Fill in the information as shown in the screen shot above. You will need to create a new flow here called Steel scrap (St). To do so switch to the DB Manager and crate it in the flow hierarchy in the waste for recovery category. Right click and select new from the menu. Complete the new flow as shown in the figure below. Then close the new flow and switch back to your unit process to enter the new flow. Properties of Drum (used) Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 10

11 Complete the plan by connecting the unit processes and fixing the Drum disassembly process to one. Fixing a processes can be done be double clicking on the process itself, and entering a 1 in the Scaling Factor box and ticking the checkbox marked Fixed. 5.1 Recycling printed paper Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 11

The processes we require for Recycling printed paper as follows: Waste paper disposal Power Grid Thermal energy for natural gas Transport (long distance)

12 The processes we require for Recycling printed paper as follows: Waste paper disposal Power Grid Thermal energy for natural gas Transport (long distance) Diesel fuel Waste paper recycling The figure below shows the details of a process that must created. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 12

of the flow hierarchy Copyright Tzu-Liang

14 And the Properties of the Waste paper recycling are as follows: Now creating the next plan Disposal and recycling printed paper No. 5 in Recycling Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 14

15 The processes we require for Disposal and Recycling Printed Paper are as follows Diesel fuel Transport (long distance) Fibers (paper) from wood Paper return Recycling Printed Paper Plan No: 4 Disposal toner Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 15

16 The processes we require for Disposal toner are as follows Toner cartridge disassembly Diesel fuel Transport (long distance) Waste incineration plant Gas and steam power plant Details of Toner Cartridge (Empty) Disassembly Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 16

The processes we require End of Life SuperCopy XR- for are as follows Diesel fuel Transport (local) Thermal energy from natural gas Power Grid Drawer disassembly Case plastic parts Disassembly

19 The processes we require End of Life SuperCopy XR- for are as follows Diesel fuel Transport (local) Thermal energy from natural gas Power Grid Drawer disassembly Case plastic parts Disassembly mechanical parts Electronic part disassembly Case metal parts disassembly Toner cartridge disassembly Plastic recycling Waste incineration plant (municipal waste) Disposal electronics scrap Steel billet (electric furnace) PC/ABS compound Gas and steam power plant Steel billet (inv). Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 19

Now we are going to create processes for all listed below a) Drawer

b) Case plastic parts disassembly Details Here we are now introducing a new concept called Parameters and the box bellow shows how to activate it Just

23 b) Case plastic parts disassembly Details Here we are now introducing a new concept called Parameters and the box bellow shows how to activate it Just click on the part that is circled in the tool bar and your parameter window will be activated. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 23

g) Drum (used) disassembly The figure below shows the details of a process that

And the Properties of the created process are as follows

35 2.3 The Use Model Create the Plan no.2: The Utilization SuperCopy XR-2 The processes and flows required for the this plan are Drum photocopier Toner cartridge photocopier Paper (wood free; uncoated) Power Grid Transport (long distance) Diesel fuel Utilization SuperCopy XR-2 Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 35

36 2.4 The Manufacturing Model Create Plan no.1: The Manufacturing SuperCopy XR-2 The processes and the flows involved are Case photocopier Drawer complete photocopier (Electro) mechanical parts photocopier Electronic parts (active) photocopier Electronic parts (passive) photocopier Toner cartridge photocopier Drum photocopier Manufacturing SuperCopy XR-2 Transport (long distance) Diesel free refinery Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 36

37 a) Case photocopier To build the Case Photocopier Case Photocopier plastic parts (from the above created plan). Case Photocopier Metal parts Glass Transport (long distance) Case Photocopier Diesel fuel. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 37

Details of case photocopier (b) Copyright

Building the Main Cycle Once we have created all the Plans and Processes, we need to put all these plans together in one plan called Life Cycle Photocopier

40 Building the Main Cycle Once we have created all the Plans and Processes, we need to put all these plans together in one plan called Life Cycle Photocopier Supercopy XR-2. Drag and Drop all these Plans in Life cycle Photocopier plan and calculate the balances. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 40

41 3 LIFE CYCLE IMPACT ASSESSMENT 3.1 Screening a Balance Result Screening is performed to check the reliability of the results, identify gaps, identifies errors of data input and to identify errors in system modeling. When screening, the quantities of mass and energy are often used. Mass view can be used to screen for errors in system modeling. Typical error in system molding is unconnected tracked flows on GABI plans. From the balance view they can be found by analyzing valuable substances/production residues flows (found of the output side of the balance). As a rule of thumb, no values contribute and from which processes they are released. The advantage of the energy view is that it shows primary energy demand in the input table (upper table of the balance window). Primary energy demand is a good indicator for environmental impacts because the environmental impacts of a product system often correlate to the primary energy demand of the same product system (however, it must be noted that it does not fully represent environmental impact). The goal of the screening is to check the actual results of the assessment against the expectation and background of the user. Focus on those process steps that constitute the main difference between the potions and check them individually. Check the relative contributions of the life cycle phases against the total result. Try to evaluate whether these seem reasonable to you. Check whether one life cycle phase dominate other to a very large extant (>99%) without obvious reason. As rules of thumb for evaluating the validity of a balance result, it can be said that: The life cycle phases contribute to the following shares: Production 10-15%, Use 50-95% and End-of-life <5%. Material production contributes about 80% and processing of these materials contributes about 20% the production phase. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 41

42 Do not blindly trust your results, even if your expectations are fulfilled! IF you find your expectations are fulfilled you must verify the plausibility of the result. There are four different energy quantities that must be viewed at Energy (net calorific value) Energy (gross calorific value) Energy ren. (gross caloric value) Energy ren. (calorific value) Commonly, the Energy (net calorific value) view is used in screening and later on for evaluating the primary energy demand. This is because the calorific value is used more often than the gross calorific value in the technical world. If desired, Energy (gross calorific value) can be used instead. However, it should be made sure that one of these quantities is used consistently during the assessment. The energy ren. (renewable) views should usually not be used for screening because they represent the demand of primary energy from hydro power. This demand does not correlate to environmental impact to a sufficient extent. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 42

43 3.1.1 Mass Balance View To view a Mass Balance 1. Select Mass at the Quantity drop-down menu. 2. Select level 1 of the process/plan hierarchy. This shows you the comparison of the product systems (represented by the respective plans). 3. Select level 2 of the flow hierarchy. This gives you a sufficient degree of detail for the screening (main flow groups): Resources Valuable substances Emissions into air Emissions into water Emissions into soil Deposited goods Production residues in life cycle Others (In most studies, some of the flow groups appear either in the input or in the output table only, some appear in both table) 4. The in/out aggregation box must be activated. 5. Examine the flow groups Valuable substances and production residues in life cycle. If values appear finding out which flows contribute to these flow groups. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 43

44 Examine the groups Valuable substances and Production residues in life cycle. By examining all the results carefully we can get an idea of how much of each material is going in to the process, how much is getting in to the environment, how much is useful, how much is a waste etc... By close observation we can conclude weather the product we design is ecofriendly or not if not getting back into the process to see what changes can be made. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 44

45 3.1.2 Energy View 1. Return to the balance just calculated. 2. Select Energy (net calorific value) from the Quantity drop-down menu. This result shows only energy from non-renewable sources. 3. Select level 2 of the flow group hierarchy. 4. Select level 1 of the process/plan hierarchy. 5. Select Relative contributions. 6. Examine which wins 7. Look at the contributions associated with cycle phases and compare against the total. 8. Select level 2 of the process/plan hierarchy. 9. Examine where the differences between both life cycles are. 10. Double click the respective column headers to unfold more details and investigate the contributions of single processes. 11. Unfold the production life cycle phase of the kitchen appliance. 12. Examine the contributions of single processes to the production life cycle phase. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 45

46 This balance sheet shows us the percentage of the stages contribution to the total life cycle. For example from the above we observe that out of 100% of the Life Cycle of the Photocopier SuperCopy XR-2, 7.49% contribution from the Manufacturing phase, 55.7% contribution from the Utilization phase and % from the Recycling phase, in this we have 40.4% from the Disposal and recycling printed paper, % from the Disposal Drum, 0.26% of the Disposal Toner, 0.374% of the End of Life SuperCopy XR-2. So from this we get an idea from which phase the contribution is more and where the concentration should be more. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 46

47 3.2 Dominance Analysis Dominance analysis is performed to identify those stages of the life cycle which contribute most to factors such as mass and energy. Total primary energy demand is often as an analysis parameter. Primary energy demand is a good indicator for environmental impacts because environmental impacts of a product system often correlate to the primary energy is of the same system (however, it must be noted that it does not fully represent environmental impact). Instead of primary energy demand, dominance analysis can be performed using many other analysis parameters, such as: specific emissions, environmental impacts or single score indicators. Method: Dominance Analysis using Primary Energy Demand Select Evaluation at the balance window. Select Energy total (net calorific value) at the Evaluation drop-down menu. This result shows the total energy required: non renewable + renewable. Select level 2 of the process hierarchy. This gives you three columns besides the column for the total life cycle: Production Use End of life Select Relative contribution. The relative contributions of the three life cycles phase (production, use, end of life) are displayed. Now we want to investigate the dominant process within the production phase: Double-click on the top of the column production and examine the contributions of each unit process. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 47

48 Conclusions of Dominance Analysis The Utilization phase of the Photocopier dominates (66.3%) the life cycle with it s weight of the copier. Therefore weight reduction is an option to lower down significantly the environmental burdens of the life cycle. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 48

49 3.3Characterization, Normalization and Evaluation The aggregation of impact indicators to a single score is often done for comparison reasons. The question often is: What is better, option A with a low acidification potential (AP) or option B, which has a higher AP, but lower GWP compared to option A? Normalization Normalization is performed to normalize different indicators to a common reference. For or example we will choose the reference annual world contribution for the respective indicator. In practice this means, the impact indicator value of the system being evaluated is divided by the impact indicator for the world per annum for this impact category. Evaluation or Weighting Evaluation is performed to emphasize the normalized impacts according to their environmental relevance. There are several approaches and methodologies to evaluation/weighting. Some are semi-scientific by setting up damage functions, other are determined using opinion polls. Single score Multiplying the normalized impact indicators with the respective weighting factors and then aggregating the results produces a single score. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 49

50 3.3.1 Characterization 1. First, calculate a balance that compares the two life cycles. 2. Look at each of the Impact Categories individually- click on Quantity View and deactivate the inputs. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 50

3.3.2 Normalization 1. Deactivate the input side of the balance 2. Select Global warming potential (GWP 100 years) at the Quantity drop-down menu 3. Select Normalization at the balance window. 4.

51 3.3.2 Normalization 1. Deactivate the input side of the balance 2. Select Global warming potential (GWP 100 years) at the Quantity drop-down menu 3. Select Normalization at the balance window. 4. Select World at the Normalization drop-down menu. This gives you two columns for the considered life cycle displaying the normalized values for GWP. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 51

52 3.3.3 Evaluation 1. Reactive the input side of the balance. 2. Select Experts at the Evaluation drop-down menu 3. Select Quantity view at the balance window This breaks down the normalized and evaluated values contributing to the single score. 4. Select Relative contribution. The relative contributions of the impact categories are displayed. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 52

53 4 THE GABI 4 ANALYST 4.1 Parameter Variation Next we will perform an interpretation using the balance results of the Life Cycle Kitchen Appliance. In this example it is demonstrated how a change in the average life of a vehicle and the weight of the Kitchen Appliance is reflected in the balance results. The interpretation uses a parameter variation to interpret the cumulative energy use for the life cycle in a liner fashion. The GABI 4 Analyst can be more intensive than in this example. Create a balance of the Life Cycle Kitchen Appliance plan in the DB Manager and expand the columns showing to level 2 using the drop down menu located at the far right of the balance. Then click on the GABI Analyst button in the toolbar. Once the Analyst opens, click on parameter variation and then click on edit scenario. Choose Scenario 1 from the drop down list. Expand Global Parameters and click on Battery Housing the mileage parameter and enter 0 and click Apply on the bottom right corner of the window. The Analyst should now look like the figure shown above. Then, using the Intermediate Steps drop down menu selects 5 to view the results in that many intervals. Click on the green arrow on the top right of the window. Now, select which environmental impact to evaluate using the drop down menus provided. First, select Outputs from the Balance Table column. Then select the Use phase form the next column and GWP 100 from the Quantity/Evaluation column and the result will be displayed below. Additional results can be displayed by following the same steps as above for other environmental or cost analysis categories. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 53

54 4.2 Scenario Analysis The second function of the GABI Analyst is the scenario analyst is which several parameters of a product system are set to specific values in order to calculate scenarios. Only the number of parameters defined in the system modeling limits the number of parameters that can be used to define a scenario. Create a balance of the Primary Battery Housing plan in the DB Manager and expand the columns showing to level 2 using the drop down menu located at the far right of the balance. The click on the GABI Analyst button in the toolbar. Once the Analyst opens, click on scenario analysis and then click on edit scenario. Choose Scenario 1 from the drop down list. Expand Global Parameters and click on Battery Housing Parameters. This provides you with a list of the global parameters define in the model. Click on the value for the weight parameter and enter 0.3. Then, expand the model tree to find the Automotive Part; Fuel Consumption unit process parameter and change the fuel_reduction factor to 0.1 and click Apply on the bottom right corner of the window. The Analyst should now look like the figure below. GABI automatically enters the data for Scenario 2 the base case. Click on the green arrow on the top right of the window. Now we will select which environmental impact to evaluate using the drop down menus provided. First, select Inputs from the Balance Table column. Then select Energy Overall (Calorific value) from the Quantity/Evaluation column and the result will be displayed below, as shown in the figure below. Additional results can be displayed by following the same steps as above for other environmental or cost analysis categories. Sensitivity analysis can also be performed in a similar manner, by clicking on the sensitivity analysis button. In this option you have the ability to vary parameters within a define range to interpret the sensitivity of your model. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 54

55 4.3 Monte Carlo Analysis Now we will use the GABI Analyst to perform to Monte Carlo analysis. Monte Carlo analysis calculates errors (due to imprecise measurement or wrong data) using stochastic method. The chosen base scenario is randomly varied between a minimum and maximum limit. The result is a calculated mean value of the chosen quantity (e.g. GWP) with a standard deviation. Using the same scenario from our scenario analysis, here the stability of the scenario will be determined based on error ranges expected from the variable input for this scenario. Looking at the figure below, the results for this scenario from an approximate bell curve as expected Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 55

56 5 CATEGORIZATION GABI allows you to categorize your processes and using standard as well as custom definitions. This is useful, for example, when, analyzing the balance for ISO purpose or for Greenhouse Gas Analysis. For ISO 14001, categorization enables you to label unit processes as internal or external and for Greenhouse Gas Analysis as scope 1, 2 or 3 under the WBCSD definition for entity analysis. The model can then be analyzed in the balance, comparing categories of unit processes. Lets view the Categorization for a one plan. Open the plan for the Life cycle Photocopier and go to the details for the Disposal Toner. By double clicking on a process, you open the process instance window. This window is the same as the window used in changing parameters as seen previously in other example. At the bottom, you will see several drop down menus. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 56

Using the table below, categorize each of the unit processes on the plan in both the enterprise and User Defined menus Process Enterprise

57 These drop down menus enables you to qualitatively define the country, type, enterprise and provide you with the ability to create user defined categories. Using the table below, categorize each of the unit processes on the plan in both the enterprise and User Defined menus Process Enterprise User defined Toner cartridge (empty) External Scope 1 disassembly Diesel free refinery External Scope 2 Truck External Scope 3 Waste incineration plant External Scope 4 Gas steam power plant External Scope 5 Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 57

58 Next, we create a balance of the Life Cycle of the Photocopier SuperCopy XR-2. Select GWP100 from the quantity menu and choose categories from the drop menu located under the in/out aggregation checkbox. Here you may filter the results based on the defined categories from the plan. Choose categories and then tick user-defined. This will enable you to view your production facilities GHG emissions categorized by scope 1, 2 and 3 as defined by WBCSD. Copyright Tzu-Liang (Bill) Tseng, All rights reserved. 58

A LIFE CYCLE ASSESSMENT-BASED COMPARISON OF ENGINEERING THERMOSET AND ALUMINUM IN AN AUTOMOTIVE UNDER-THE-HOOD APPLICATION

A LIFE CYCLE ASSESSMENT-BASED COMPARISON OF ENGINEERING THERMOSET AND ALUMINUM IN AN AUTOMOTIVE UNDER-THE-HOOD APPLICATION David P. Evers, Sigrid ter Heide, Tanis J. Marquette Hexion Inc. 180 E. Broad