Application of LCA & EcoDesign in Eco-Products Development: Case Study …€¦ · · 2005-12-20Eco-Products Development: Case Study for Eco-compressor by ... Target Product / Parts
Post on 18-Apr-2018
218 Views
Preview:
Transcript
Application of LCA & EcoDesign in Eco-Products Development:
Case Study for Eco-compressorby
Dr. Thumrongrut Mungcharoen 1,
Mr. Suradej Boonyawatana 2
1 National Metal and Materials Technology Center (MTEC), National Science and Technology Development Agency (NSTDA),
Ministry of Science and Technology2 Kulthorn Premier Co., Ltd.
International Workshop on“Capacity Building on Life Cycle Assessment in APEC Economies”Bangkok, Thailand, December 15 - 16, 2005
2
Contents 1. Environment Legislations Overview2. Introduction to LCA 3. Introduction to EcoDesign4. Pilot Project: Eco-compressor
4
Law for the Promotion of the Effective Utilization of Resources (Promote “3Rs) (2001)
Basic Environment Law
Waste Disposal and Public Cleaning Law
Law on Promoting Green Purchasing (2001)
Basic Law for Establishing the Recycling-based Society
Containers and Packaging Recycling Law (2000)Home Appliances Recycling Law (2001)Food Waste Recycling Law (2001)Construction Materials Recycling Law (2002)Automobile Recycling Law (2002)Fluorocarbons Recovery and Destruction Law
Recycling lawsfor individual
fields
Japan Legislation (all laws below are already enforced)
Source: Eco-management Institute (Japan)
5
Other Countries
China: WEEE/RoHS (Aug 2006)USA: California; EE Recycle Law & RoHS
(enforce together with EU)Hawaii; Ban PBDE (Jan 2006)
7
Product Life Cycle “From Cradle to Grave”
Impacts on • Human health• Ecosystems• Resources
2. Introduction to LCA
8
What is LCA?Life Cycle Assessment (LCA) is an environmental assessment tool for evaluation of impacts that a product (or service) has on the environment over the entire period of its life – from the extraction of the raw materials from which it is made, through the manufacturing, packaging and marketing processes, and the use, re-use and maintenance of the product, and on to its eventual recycling or disposal as waste at the end of its useful life
Source: UNEP (1999)
9
Road Map - ISO 14000Management
Systems
ISO 14004 (EMS)
general guidelineson principles, systems
& supportingtechniques
ISO 14001 (EMS)
specification withguidance for use
Evaluation &Auditing Tools
EnvironmentalPerformance
Evaluation (EPE)
ISO 14031 guidelines
EnvironmentalAuditing (EA)
14010 general principles
14011-1 audit procedures
14012 qualification criteriafor environmentalauditors
Product-OrientedSupport Tools
Life Cycle Assessment (LCA)14041 general principles &
practices14042 life cycle inventory analysis14043 life cycle impact assessment14044 life cycle improvement
assessment
Environmental Labelling (EL)14020 basic principles for all
environmental labelling14021 terms & definitions14022 symbols14023 testing & verification14024 guiding principles, practices
& criteria for certificationprograms
10
ISO 14040 Life Cycle Assessment, Principles and Framework
Life cycle assessment framework
Goal and scopedefinition
Inventoryanalysis
Impactassessment
Inter-pretation
Direct applications:- Product developmentand improvement
- Strategic planning- Public policy making- Marketing- Other
Source: ISO 14040 (ISO, 1997)
11
Foreground Data
Materials
Electricity Fuels
Manufacturing Use Disposal
Mining
Background Data
Life Cycle Inventory Analysis (LCI)
Ref: Dr.INABA, AIST
12
Utilization of LCA Voluntary
ImprovementMarketing
Reflection to Social/Economic
SystemsConsumption
Activity
Design for Environment (DfE)
Appealing (Public Relations)
Environmental ReportsEnvironmental Labeling
Environmental EducationLifestyle Review
GreenProcurement
Environmental Administration(Support for recycling, etc)
Information DisclosureEnvironmental Management System
Recycling DesignProcess Improvement
LCA
Ref: Ishizaka, Nagano prefecture
13
3. Introduction to EcoDesignProduct Design is a critical determinant of a manufacturer’s competitivenessNational Research Council, USA: estimates that 70% or more of the costs of product development,manufacture and use are determined during theinitial design stagesBad design leads to inefficient use of resourcesand excessive wasteTrade Barriers using environmental aspects(packaging / hazardous substances / product recyclability etc.)
14
What is EcoDesign?EcoDesign is a design approach that leads to a profitable balance between ecological and economical requirements when developing products.The total life cycle of a product is the basis on which EcoDesign builds its strategies. From cradle to grave, environmental issues are considered for each stage the product goes through.
15
What can be achieved with EcoDesign?
Considerable reduction in environmental load (e.g., 30-50% or higher) – often feasible in short termSaving of materials and energyReduction in wasteInnovative product designConsiderable reduction in costs
• A win-win situation – benefits for both business and environment• Through a number of small steps - rather than a single large breakthrough• Take only a little logical thinking on familiar products
16
UNEP Eco-Strategies Wheel
1Selection of low-impact materials••Non-hazardous materials •Non-exhaustable materials •Low energy content materials •Recycled materials •Recyclable materials
0•New Concept Development
•Dematerialisation•Shared use of the product •Integration of functions •Functional optimization of product (components)
2Reduction of material•Reduction in weight •Reduction in (transport) volume
3Optimization of production techniques•Alternative production techniques •Fewer production processes •Low/clean energy consumption •Low generation of waste •Few/clean production consumables
4Efficient distribution system••Less/clean packaging •Efficient transport mode •Efficient logistics
5Reduction of the environmentalimpact in the user stage•
•Low energy consumption •Clean energy source •Few consumables needed during use •Clean consumables during use •No energy/auxiliary material use
6Optimization of initial life-time••Reliability and durability •Easy maintenance and repair •Modular product structure •Classic design •User taking care of product
7Optimization of end-of-life system•Reuse of product •Remanufacturing/refurbishing •Recycling of materials •Clean incineration
+- +-
Existing product
Priorities for the new product
17
EcoDesign Process Flow
Detailed Design
Approval
Quantitative (Final) Design Review
Target Product / Parts
Analysis and Evaluation of the Present Design
Conceptual Design
Phase IPlanning
Phase IIAnalysis &Generation
Phase IIIDesign &
Development
Phase IVVerifying
& Approval
LCAEco-Indicator
QFDE
DFE Checklist
EcoDesign Tools EcoDesign Phases
Qualitative Design Review
Product Concept Making
18
17%5%
7%
19%
2%4% 46%
Air conditionerRefrigeratorRice cookerFansWashing MachineWater boilerOther
Source: Conclusion Report (2000) of “Consulting Assignment-Load Research Program”, EGAT
Electricity consumption in residential sector
Source: EGAT Public Company Ltd. (2000)
Energy Consumption of Various Home Appliances
19
Environmental impact of compressor usage
Electricity ConsumptionElectricity Consumption of Refrigerator is 20% of residential sectorAcidification & Green House Effect from Energy Consumption
Solid wasteSteel scrap, Slag
CFC Substance EmissionOzone depletion
20
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
2000 2001 2002 2003
Year
Cap
acity
(uni
t/ ye
ar)
Rotary Com.Scroll Com.Reciprocating Com.
Production Capacity of each type compressor in Thailand
Source: Siam Compressor Industry Co., Ltd. (2003)
21
Refrigerator & compressor production capacity in Thailand
0
1,000,000
2,000,000
3,000,000
4,000,000
5,000,000
6,000,000
7,000,000
1999 2000 2001 2002
Year
Pro
duct
ion
(Uni
ts/y
ear)
Compressor
Refrigerator
22
Export Value of Refrigerator in Thailand
-
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
1998 1999 2000 2001 2002 2003
Year
Expo
rt v
alue
(mill
ion
baht
/yea
r)
Domestic refrigeratorComercial refrigerator
23
4. Pilot Project: Eco-compressor
Collaborative project between government and industry strategic partnerSigning an cooperative agreement between MTEC and SUE (KPC) on August 27, 2003As a pilot project of the NETH program of GMTAP
24
Demonstration Project to Produce Prototype of a more Environmental Friendly Compressor
Redesign partsCast iron parts
25
Expected Output of Pilot Project
• A good demonstration project for Thailand that combines both LCA and EcoDesign into one project.
• Creat a group of core researchers who have practical experience in LCA and EcoDesign.
• The production processes of motor case + cylinder & piston + slider are expected to be reduced ~50% by changing from “Casting” to “Sintering”. Reduce energy, resources,and environmental impacts from the production.
• Developing strong relationship among MTEC & private company & Japanese counterparts (e.g. JETRO, JODC)
26
Current SituationEco-Design Part
o JODC-Expert dispatch: Mr.Akira Arai, visit 3 times (7-11 June 04, 22-26 Nov 04, 7-11 Feb 05)
o Review design & detail design of the compressor partso Making mold prototypes (connecting rod & piston)o Finite Element Analysis (connecting rod & crankcase)o Making eco-parts (connecting rod & piston)o Friction wear resistance test (bush + connecting rod & piston)o Performance & reliability testo Mechanical testing of the connecting rod
29
Performance Test of Compressor
Type
Current modelNew model I (connecting rod + piston + crankcase (bush) as sinter)
Cooling capacity (BTU/hr)
468.3459.1
COP (W/W)
1.5031.549
Noise (dB A)
36.4636.10
30
Goalto determine the net improvement of environmental impact of a new prototype compressor (comparison of a conventional & new prototype compressor)
Product:Reciprocating compressor (model 110 W)
Functional unitRefrigerated temperature at 5o C for 10 years with an ambient temperature at 32o C
LCA Part
31
Simplified Process Tree for a Compressor’s Life-Cycle
main assembly
PE Al ingot
injection
disposal
use in refrigerator
cast iron
machining
steel sheet
stampingforming
small parts
forming
painting/packing
injectionmoulding
electricity
washing
Cu tube
forming
shell assembly
silicon steel
cutting cutting
Cu wire
stator assembly
rotor assembly
suction assembly
32
Plastics
Aluminium
Copper
Steel
Paints
Hot Rolled SheetCold Rolled Sheet
Silicon SteelCast Iron
Parts Supplier
ManufacturingPlant
Production of Compressor
Compressor
33
Emission to Water
pH 7.4BOD xxx kgCOD xxx kgSS xxx kgGrease & Oil xxx kgWaste water xxx L
Materials/Resources
Steel xxx kgCast Iron xxx kgCopper xxx kgAl xxx kgPlastic xxx kgPaint xxx kgBA oil xxx LGear Oil xxx LNUTO Oil xxx LTelluse Oil xxx LCutta Oil xxx LMacron Oil xxx LLubricant xxx kgTrichloroethylene xxx LNano water xxx LWater xxx L
Emission to Air
CO xxx kgCO2 xxx kgNOX xxx kgSOX xxx kgVOC xxx kgH3PO4 xxx kgMn xxx kgEthylene Glycol xxx kg
Compressor Factory
Energy Uses
Electricity xxx kWhLPG xxx m3
Fuel Oil xxx L
Solid Waste
Steel scrap xxx kgCast iron waste xxx kg
Inventory Data of the Compressor
Compressor
34
Main Materials of Compressor
Steel71.93%
Others0.24%
Al2.21%
Paint0.21%
Plastic0.63%
Cast iron14.25%
PM part0.29%
Copper10.24%
35
-0.1
-0.05
0
0.05
0.1
0.15
0.2
Materials Production Disposal
Sing
le s
core
(Pt)
summer smogwinter smogcarcinogensheavy metalseutrophicationacidificationozone layergreenhouse
Life Cycle Impact Assessment of Compressor
36
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
Statorcore
Magnetwire
Rotor core Cast ironparts
Shell Al ingot Crankshaft
Sing
le s
core
(Pt)
summer smogwinter smogcarcinogensheavy metalseutrophicationacidificationozone layergreenhouse
Life Cycle Impact Assessment: main component
37
Life Cycle Impact Assessment based on Categories
Analyzing 1 p assembly 'Main Process Compressor'; Method: EDIP/UMIP 96 / EDIP World/Dk / characterization
%
0
10
20
30
40
50
60
70
80
90
100
Global w armi
Ozonedepletion
Acidif ication
Eutrophicati
Photochemi
Ecotoxicity
Ecotoxicity
Ecotoxicity soil
Humantoxicit y
Humantoxicit y
Humantoxicit y
Bulkw aste
Hazardous
Radioactive
Slags/ashes
Resources
Stator Assy OP1 Cylinder Assy Plate Support Assy Valve Head Assy Spring AssyDisch pipe Assy Suction Muf f ler Assy Shell A Assy(Alkaline) Shell B Assy(Alkaline) Compressor Assy Dry of OvenCS Welding Leak Test Pre Treatment ED Painting ED Oven N2 Charg(Fianl Line)
100 100 100 100 100 100 100 100 100 100 100 100 100
0
100 100
38
ConclusionsThis Eco Compressor project is the first formal LCA-EcoDesign combination project in ThailandIt is still a learning RD&E process between KPC+MTEC with a technical support from Japan through GPPThe final result of this project is expected to be in the 3rd quarter of 2006
39
ACKNOWLEDGEMENT
The technical support from Japanese Government through Green Partnership Plan (GPP) is acknowledged
Dr. Thumrongrut MungcharoenCleaner Technology Advancement Program (CTAP) National Metal and Materials Technology Center (MTEC)National Science and Technology Development Agency
Tel: (662) 644-8150-9 ext. 434 Fax: (662) 644-8041E-mail: thumrongrut@mtec.or.thwww.mtec.or.th/th/research/ctap
top related