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Carbon Fiber LCA data in EcoCalculatorAn essential extension

Composites Europe - November 8, 2018

Overview

• Introduction and status Ecocalculator

• LCA for Carbon fiber

• Next steps

FRP Life Cycle“Innovative Concepts: Many Different Products in Many, Many Different Applications”

Composite manufacturing loop“Days”

Input

ReinforcementMatrixAdditives, etc.

Packaging

transport

Conversion

ProcessUtilitiesWasteEmissions

Hardware

Service life“10 – 50+ years”

TransportationInfrastructure

MarineEnergy

Anti-Corrosion

End of Use

Co-ProcessingCement

Energy recoveryMaterial recovery

Eco Calculator

Very Diverse Very, Very Diverse

Eco Impact gain by replacingother materials, longevity, etc.

Processes in PlaceGuidance document on the

interpretation of Waste Framework Directive WFD 2008/98/EC

Ecocalculator only for cradle to gate manufacturing: can be used as input for full life cycle calculations

System Boundary: Cradle to Gate

Production process moulded composite

product

Moulded composite

product

CoreFillerResinFiber

Transport

Use and maintenance

End of life

Extraction of resources

AuxiliariesAdditives

Transport

Coating

Energy

EmissionsWater

Production intermediates

Waste

Transport

Necessary process

Optional process

System boundary

• EuCIA (www.eucia.eu) has developed the Eco Calculator in cooperation with EY Cleantech and Sustainability Services and Biinc.

• The Eco Calculator allows composite manufacturers to calculate the environmental impact of their products, without the need of a deep know-how of Life Cycle Assessment processes.

• The tool generates an Eco Report, a Summary Report and SimaPro 8.2 Export – Using a transparent and uniform sector methodology for processes following ISO 14.040/044

– Based on Industry generated, peer reviewed, quality data as well as material data from eco inventories* i.e. EU average energy mix is used

– Conversion processes based on industrial averages as well possibility to modify/own input

– Output can be used as input: manufacturing of product input for full life cycle calculations

– The Eco Factsheet is based on EU industry average figures for the conversion processes. Third party verification on the processes has not been performed and this is therefore not an Environmental Product Declaration (EPD).

• The Eco and Summary reports are to be shared with clients and other stakeholders, to fulfill the need for accurate and specific environmental information.

• The tool is web-based, easy to use

• The tool is free http://ecocalculator.eucia.eu/

• The tool is launched http://bit.ly/29pRJDn

5

Initiative EuCIA: Eco Calculator for Composite Parts

* GFE (http://www.glassfibreeurope.eu); Plastics Europe (www.plasticseurope.org); AVK (www.avk-tv.de); Ecoinvent 3.1

Main Industry Processes Covered

In modelPultrusion

Resin infusion

Resin transfer moulding

SMC Pressing

SMC Compounding

*TP compounding

*TP Injection molding

*LFT/UD tape

* modelled

6

MissingCentrifugal casting/Filament winding

Hand lamination

Spray-up

Pre-forming

Prepreg autoclaving

BMC Compounding

BMC Pressing

EuCIA continues to work on missing process data. Questionnaire for process parameters has been designed; available through [email protected] - Input covered under NDA

Gaps

Materials• Carbon Fiber

• Some EP Curing agents

• Flame retardants

Processes• several processes

• Some intermediate products (woven roving and non crimp fabric)

Collection industry data continues, also driven by OEM’s

Carbon Fiber LCA data

• Industry input seeked for, but not obtained

• Eco invent & Literature Data– KUL(1)

– ORNL (2)

(1) Duflou JR, De Moor J, Verpoest I, Dewulf W. Environmental impact analysis of composite use in car manufacturing. Cirp Annals-Manufacturing Technology. 2009;58(1):9-12.

(2) Das S. Life cycle assessment of carbon fiber-reinforced polymer composites. International Journal of Life Cycle Assessment 2011. p. 268-82.

Carbon Fiber Manufacturing

• Automotive grade• PAN based 95% acrylonitril and 5%

vinyl acetate or methylacrylate• PAN conversion to CF

– Various efficiencies are reported(1,2): 48 -> 58%

– Our calculation uses 53% as a average

• EU Average Energie mix

https://www.energy.gov/sites/prod/files/2016/09/f33/fcto_h2_storage_700bar_workshop_3_warren.pdfhttp://www.carbon-fiber.com/eccf.pdf

Acrylonitril to PAN precursor for Carbon Fiber

Automotive grade: 95% AN and 5 % MA or VA

Details PAN to Carbon Fiber Conversion Process

PAN to Carbon FiberC3H3N -> carbon fiber + CO/CO2, HCN, NH3, etc.

Abatement technologies are not included: no good data, but also a very small contribution compared to overall process

Methods used:1. Cumulative energy demand2. Greenhouse Gas Protocol V1.01 / C02 eq (kg)3. ILCD 2011 Midpoint+ V1.06 / EU27 2010, equal weighting

AN

Conversion % PAN

Conversion % PAN input CF CF

Delta PAN/CF

Source… Data Unit Source… Data Unit Source… Data Unit Data Unit

Ecoinvent CED 82,24264MJ N/A ELCD CED 115,3003MJ 53% 217,55Literature CED 770,9 MJ 553,34MJ

Ecoinvent GHG 2,821385kg N/A ELCD GHG 5,683081kg 53% 1,07E+01Literature GHG 38,9 kg 2,82E+01kg

EcoinventClimate change 2,820064kg CO2 eq N/A ELCD Climate change 5,702157kg CO2 eq 53% 1,08E+01Literature Climate change 39,0 kg CO2 eq 2,82E+01kg CO2 eq

EcoinventOzone depletion 1,96E-07kg CFC-11 eq N/A ELCD Ozone depletion 3,2E-07

kg CFC-11 eq 53% 6,03E-07Literature Ozone depletion 3,537E-06

kg CFC-11 eq 2,93E-06

kg CFC-11 eq

Ecoinvent

Human toxicity, non-cancer effects 3,35E-07CTUh N/A ELCD

Human toxicity, non-cancer effects 7,41E-08CTUh 53% 1,40E-07Literature

Human toxicity, non-cancer effects 5,116E-06 CTUh 4,98E-06CTUh

Ecoinvent

Human toxicity, cancer effects 6,68E-08CTUh N/A ELCD

Human toxicity, cancer effects 6,47E-09CTUh 53% 1,22E-08Literature

Human toxicity, cancer effects 1,295E-06 CTUh 1,28E-06CTUh

EcoinventParticulate matter 0,001667kg PM2.5 eq N/A ELCD Particulate matter 0,001009

kg PM2.5 eq 53% 1,90E-03Literature Particulate matter 0,0101048

kg PM2.5 eq 8,20E-03

kg PM2.5 eq

EcoinventIonizing radiation HH 0,120637kBq U235 eq N/A ELCD

Ionizing radiation HH 0,380334

kBq U235 eq 53% 7,18E-01Literature

Ionizing radiation HH 10,934871

kBq U235 eq 1,02E+01

kBq U235 eq

Ecoinvent

Ionizing radiation E (interim) 4,61E-07CTUe N/A ELCD

Ionizing radiation E (interim) 3,76E-06CTUe 53% 7,09E-06Literature

Ionizing radiation E (interim) 3,924E-05 CTUe 3,22E-05CTUe

Ecoinvent

Photochemical ozone formation 0,006219kg NMVOC eq N/A ELCD

Photochemical ozone formation 0,018073

kg NMVOC eq 53% 3,41E-02Literature

Photochemical ozone formation 0,07587

kg NMVOC eq 4,18E-02

kg NMVOC eq

Ecoinvent Acidification 0,019867molc H+ eq N/A ELCD Acidification 0,025009molc H+ eq 53% 4,72E-02Literature Acidification 0,13858 molc H+ eq 9,14E-02

molc H+ eq

EcoinventTerrestrial eutrophication 0,060164molc N eq N/A ELCD

Terrestrial eutrophication 0,063263molc N eq 53% 1,19E-01Literature

Terrestrial eutrophication 0,25244 molc N eq 1,33E-01molc N eq

EcoinventFreshwater eutrophication 0,00032kg P eq N/A ELCD

Freshwater eutrophication 2,69E-05kg P eq 53% 5,08E-05Literature

Freshwater eutrophication 0,01235 kg P eq 1,23E-02kg P eq

EcoinventMarine eutrophication 0,0122kg N eq N/A ELCD

Marine eutrophication 0,006365kg N eq 53% 1,20E-02Literature

Marine eutrophication 0,02632 kg N eq 1,43E-02kg N eq

EcoinventFreshwater ecotoxicity 9,188386CTUe N/A ELCD

Freshwater ecotoxicity 0,335532CTUe 53% 6,33E-01Literature

Freshwater ecotoxicity 124,88113 CTUe 1,24E+02CTUe

Ecoinvent Land use 1,982205kg C deficit N/A ELCD Land use 0kg C deficit 53% 0,00E+00Literature Land use 18,14196 kg C deficit 1,81E+01kg C deficit

Ecoinvent

Water resource depletion 0,008189m3 water eq N/A ELCD

Water resource depletion 1,62E-05

m3 water eq 53% 3,06E-05Literature

Water resource depletion 0,07965

m3 water eq 7,96E-02

m3 water eq

Ecoinvent

Mineral, fossil & ren resource depletion 9,71E-05kg Sb eq N/A ELCD

Mineral, fossil & ren resource depletion 2,79E-06kg Sb eq 53% 5,26E-06Literature

Mineral, fossil & ren resource depletion 0,00012 kg Sb eq 1,14E-04kg Sb eq

CED 771 MJ/kgGHG 38,9 kg CO2eqEco footprint carbon fiber

Next steps

• Put data in Ecocalculator and approach in parallel parties for feedback

• Publish data at conferences

• Elect industry input

Thank you!

For more information, please contact:

[email protected]