LCA Modeling for Automotive Applications Russ Balzer WorldAutoSteel
Automotive Group of the World Steel Association MEMBER COMPANIES: Ansteel Arcelor Mittal Baosteel China Steel JFE JSW Steel Hyundai Steel Kobe Nippon Steel & Sumitomo Nucor POSCO Severstal SSAB Tata Steel ThyssenKrupp USIMINAS U. S. Steel voestalpine
Tailpipe Emissions Standards Are Becoming more stringent Across The Globe Source: International Council on Clean Transportation August 2011
The Problem with Tailpipe-only GHG Emission Regulations Material Production GHG comparison for a functionally equivalent component - example Mid-Range CO 2 e Estimated Part Weight (kg) (kg CO 2 e) Mild Steel Advanced High-Strength Steel Aluminium 2.3 100 2.3 75 11.3 67 230 173 757 Magnesium 46.0 50 2300 Carbon FRP 22.0 45 990
An unintended consequence of tailpipe-only regulations Vehicle Production emissions Tailpipe emissions Cost Result: potential for overall higher GHG emissions at higher cost
What Does The Future Hold? Effect of increased powertrain efficiency and alternative fuels on carbon footprint Battery electric vehicle Fuel economy or tailpipe emissions standards are not enough to ensure overall reductions in automotive GHG emissions.
Life Cycle Assessment (LCA) Source: worldsteel
WorldAutoSteel Operations WorldAutoSteel Automotive LCA Advocacy we re on a journey Life Cycle Assessment Members Modeling Customers Mission: Advance and Communicate Messaging Communications implementation Policy Makers - Asia Case Studies Policy Makers U.S. Policy Makers - EU Objective Influence policy and material selection decisions to include a life cycle assessment methodology, and metrics beyond tailpipe emissions. Technical Development Integration with worldsteel LCA Experts for methodology guidance, consistency and market alliance. Continuous modeling improvements Development of Case Studies and Key Messaging Engage Policy Makers Develop Global Steel Team LCA & Automotive experts Ongoing Commitment Achieve alignment Provide communication tools Build on U.S. program Apply lessons learned Action Plan for Regional Mtgs
Automotive Materials Comparison Models UCSB Automotive Materials Energy and GHG Comparison Model Design Advisor autolca
Full-vehicle model using peer-reviewed LCA methodology GHG and Total Primary Energy UCSB Automotive Materials Greenhouse Gas Comparison Model
UCSB Automotive Materials Greenhouse Gas Comparison Model 7 Powertrains 5 vehicle classes 3 driving cycles 2 Recycling Methodologies MSR CSE
UCSB Automotive Materials Greenhouse Gas Comparison Model Fully parameterized and transparent End of Life Management of Vehicle Collection Shredder Material Recycling Recovery Rate in % in % in % in % Conventional Steel Flat carbon steel 97% 98% 95% 90.3% Long & special steel 97% 98% 95% 90.3% Cast iron 97% 98% 95% 90.3% AHSS (ULSAB-AVC) Flat carbon steel 97% 98% 95% 90.3% Long & special steel 97% 98% 95% 90.3% Cast iron 97% 98% 95% 90.3% Aluminum Rolled aluminum 97% 90% 90% 78.6% Extruded aluminum 97% 90% 90% 78.6% Cast aluminum 97% 90% 90% 78.6% Composites SMC 0.0% GFRP 0.0% CFRP 0.0% Magnesium Cast Mg 97% 90% 90% 78.6% Zirmax AZ91 Alloy 97% 90% 90% 78.6% Rolled Mg 97% 90% 90% 78.6%
Design Advisor Vehicle system level analysis of component material options Comparison of mass, cost, GHG emissions
Design Advisor Multiple Secondary Mass Change methodologies
1 3 5 7 9 11 13 15 17 19 21 Design Advisor nominal vehicle better Comparison Base-line to Perturbed resized vehicle better -2 0 2 Perturbed Performance nominal resized difference % of nom 20.00 18.00-2.00-10% 18.00 16.00-2.00-11% -0.60 1507 1505-2.60 0% Built-in Sensitivity Analysis Run Analysis 40 96 56.08 140% -0.80 55.28 11640 11635-5.27 0% 8988 8984-4.07 50.01 51.21 +10% 0-10% 80 260 180.94 227% 4462 4460-1.90 0% 4541 4720 179.03 4% -38 0 38.26-100% -1869-1868 0.70 0% -1907-1868 38.97-2% 34375 34360-15.56 0% 37010 37212 202.43 1% Competitor component mass Nominal vehicle mass Vehicle mass compounding Fuel consumption mass sensitivity Fuel CO2/unit Reset parameter values Material CO2/kg - Original Part Material CO2/kg - Competitor Part Recy cling Rate - Original Part Recy cling Rate - Competitor Part Recy cling CO2/kg - Original Part Recy cling CO2/kg - Competitor Part
Design Advisor DA Workshop When Friday, June 7 th, 8:30 AM 3:00 PM Where Steel Market Development Institute Southfield, MI Sign up at: www.worldautosteel.org
Importation of UCSB methodology into GaBi modeling software Ganzheitliche Bilanz ( Holistic Balance ) Connection to GaBi datasets Standardized data Full LCI data GaBi is used globally
GaBi datasets 4700 LCI (Lifecycle Inventory) Datasets Database upgrades every year Standardization of methods and boundaries across datasets
Full LCI data means we can explore impacts beyond GWP Product Environmental Footprint TRACI
GaBi is used by major OEMs all over the world
Toyota Venza Study in Phase 1 report released 2010 AHSS-intensive Multi-material Phase 2 report released 2012 Al-intensive
Toyota Venza Study in
Toyota Venza Study in Low Development Phase 1 AHSS intensive High Development Phase 1 Multi-material (AL, CFRP, Mg) High Development Phase 2 Al intensive Table 8 - Summary of Results - TRACI Categories Baseline Vehicle Contender Vehicle 1 Contender Vehicle 2 TRACI 2.1, Global Warming Air [kg CO2-Equiv.] 35967 36845 36491 TRACI 2.1, Acidification Air [kg SO2-Equiv.] 74.042 107 101.87 TRACI 2.1, Eutrophication Air [kg N-Equiv.] 2.6923 3.6459 3.4621 TRACI 2.1, Ozone Depletion Air [kg CFC 11-Equiv.] 0.000092449 0.000033052 0.000036187 TRACI 2.1, Smog Air [kg O3-Equiv.] 803.91 1409.1 1304.5 TRACI 2.1, Acidification Water [kg SO2-Equiv.] 0.059416 0.026359 0.027523 TRACI 2.1, Eutrophication Water [kg N-Equiv.] 3.3658 3.3834 3.1089 TRACI 2.1, Ecotoxicity (recommended) [CTUeco] 16.442 10.632 10.57 TRACI 2.1, Human toxicity, cancer (recommended) [CTUh] 2.5699E-07 8.1986E-07 7.4055E-07 TRACI 2.1, Human toxicity, non-canc. (recommended) [CTUh] 3.6783E-08 9.1338E-08 8.2117E-08 TRACI 2.1, Human Health Particulate Air [kg PM2,5-Equiv.] 9.9785 20.051 18.714 TRACI 2.1, Resources, Fossil fuels [MJ surplus energy] 63298 57277 57727
Toyota Venza Study in Low Development Phase 1 AHSS intensive High Development Phase 1 Multi-material (AL, CFRP, Mg) High Development Phase 2 Al intensive Table 5 - Summary of Results - PEF Categories Baseline Vehicle Contender Vehicle 1 Contender Vehicle 2 Global Warming Potential [kg CO2-Equiv.] 35286 36263 35898 IPCC global warming, excl biogenic carbon [kg CO2-Equiv.] 35967 36845 36491 Ozone Depletion Potential [kg R11-Equiv.] 0.000079658 0.000028465 0.000031166 Photochemical Oxidant Formation [kg NMVOC] 37.569 64.083 59.275 Acidification Potential [Moles of N or S-Equiv.] 26.042 38.904 36.94 Terrestrial Eutrophication [Moles of N or S-Equiv.] 238.95 388.79 368.23 Aquatic Eutrophication [kg P eq] 0.028773 0.044548 0.032956 Ecotoxicity (USEtox) [CTUeco] 1395.6 1748.2 1642.9 Human Toxicity, Cancer (USEtox) [CTUh] 5.7473E-06 8.9406E-06 8.6278E-06 Human Toxicity, Non-canc. (USEtox) [CTUh] 0.0017859 0.0021853 0.0021265 Particulate Matter/Respiratory Inorganics [kg PM2,5-Equiv.] 9.6796 19.058 17.641 Resource Depletion (Fossil and Mineral) [kg Sb-Equiv.] 0.12151 0.15158 0.1567
Downloads and Workshops See the bookmark and flier included in your bag. Workshop Free Downloads Design Advisor Workshop June 7, 2013 For more information and registration visit worldautosteel.org @ www.worldautosteel.org
LCA Modeling for Automotive Applications Thank You! Questions? Please contact me at russ.balzer@worldautosteel.org
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