Life Cycle Assessment of Sugarcane-Based Polyethylene

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1 Life Cycle Assessment of Sugarcane-Based Polyethylene Shawn Hunter, PhD LCA Expert Group, The Dow Chemical Company, Midland, MI USA Bruno Pereira Polyethylene Business, The Dow Chemical Company, São Paulo, SP BR Rich Helling, ScD Process Development and Analysis, The Dow Chemical Company, Midland, MI USA October 1, 2008

2 Summary Sugarcane-based PE vs. Fossil-based PE Advantages Global Warming potential Fossil Fuel demand Acidification potential Tradeoffs Land occupation Water demand Eutrophication potential Page 2

3 Cane to PE Project Background Dow Crystalsev Joint Venture announced in 2007 Produce world s first fully-integrated sugarcane-based polyethylene facility in Brazil 350 KTA, 2011 Start up Alignment with Dow s Corporate Sustainability Theme and Crystalsev s Diversification Strategy Crystalsev/SEV Industry leader in cane/ethanol technology Dow World leader in polyethylene production Cane PE Life Cycle Assessment Dow s 2015 Sustainable Chemistry Goal Life cycle view of products Marketing & Communications Transparency Page 3

4 LCA Goal & Scope Goal: Compare life cycle impacts of process-specific Cane-based PE* with industry-average Fossil-based PE PE Product is the same Eco-profile comparison possible Cane-based PE Eco-profile Grow Cane Make EtOH Make C 2 H 4 Make PE Transport PE Excluded from Analysis Make PE Product Use PE Product Dispose of PE product Extract & Refine Oil/Gas Make C 2 H 4 Make PE Fossil-based PE Eco-profile Functional Unit: 1 kg of PE, ready for shipment to customer Out of Scope: Land Use Change - to be addressed by local experts *PE = LLDPE = linear low density PE Page 4

5 Cane to PE Process Highlights Cane and Ethanol production Best in class technology Internal Recycling: Nutrient-rich by-products (vinasse, filter cake) and process water returned to fields Mechanical Harvesting Bagasse (biomass residue) combusted to produce energy Produces all steam and electricity required for entire Cane to PE process Produces surplus electricity, sale to grid Ethanol to Ethylene Improved dehydration technology Ethylene to PE Dow proprietary Solution Technology Page 5

6 Best In Class Ethanol: Internal Recycling Nutrient-rich by-products (vinasse, filter cake) and process water returned to fields Page 6

7 Best In Class Ethanol: Mechanical Harvesting Page 7

8 Best In Class Ethanol: Biomass to Energy Bagasse (biomass residue) combusted to produce energy Produces all steam and electricity required for plant Produces surplus electricity, sale to grid Page 8

9 Cane to PE Process Highlights Cane and Ethanol production Best in class technology Internal Recycling: Nutrient-rich by-products (vinasse, filter cake) and process water returned to fields Mechanical Harvesting Bagasse (biomass residue) combusted to produce energy Produces all steam and electricity required for plant Produces surplus electricity, sale to grid Ethanol to Ethylene Improved dehydration technology Ethylene to PE Dow proprietary Solution Technology Page 9

10 Cane to PE Process* CO 2 N 2 O Boiler Emissions OUTPUT Furnace Emissions Flare Emissions Fugitive Emissions Vent Emissions Flare Emissions CO 2 CANE: Sugarcane Production Cane EOH: Ethanol Production EtOH E2E: Ethylene Production C 2 H 4 PE: LLDPE Production Cane-based PE Diesel Use Fertilizer Pesticides Herbicides Equipment Soybean Production Water Water Treatment Equipment Buildings Anti-foam INPUT Refrigerant Flare Fuel HT Fluid Catalyst Waste Treatment Comonomers Reaction Solvent Fossil PE Transportation Hydrogen Catalyst Solvent Waste Treatment *Major input and output categories shown Page 10

11 Life Cycle Modeling Cane-based PE Data Sources Cane to PE process: Detailed Design Data Comonomer production: Consulting Report Data Cane to PE process inputs: Ecoinvent 2.01 P3:Cane PE P1:Inputs P2:Outputs T1:Cane PE Production Fossil-based PE Data Source PlasticsEurope Data UMBERTO Model developed Cut-Off Criteria At least 99.6 mass% of inputs to each stage of cane-to-pe process modeled Allocation: All burdens allocated to Cane-based PE Page 11

12 Life Cycle Impact Assessment Impact Category Assessment Method Global Warming IPCC 2001 Energy Demand Cumulative Energy Demand (CED) Acidification CML 2001 Eutrophication CML 2001 Land Occupation CML 2001 Water Demand Valuation System Created Page 12

13 Global Warming Potential (kg CO2 eq/kg LLDPE) Global Warming Fossil-based PE -2.0 Cane-based PE KTA plant = 1.3 million tons CO 2 avoided/yr Page 13

14 Global Warming Potential (kg CO2 eq/kg LLDPE) Global Warming CANE and EOH E2E and PE Emissions + Credit in Canebased = PE Total Canebased PE Agricultural operations dominates GHG emissions Page 14

15 Cumulative Energy Demand (MJ/kg LLDPE) Energy Demand nuclear biomass (renew able) fossil 20 0 Fossil-based PE Cane-based PE Uses 80% less Fossil Energy Page 15

16 Acidification Potential (g SO2 eq/kg LLDPE) Acidification Fossil-based PE Cane-based PE Low N, S content of bagasse = low acid gas formation Page 16

17 Eutrophication Potential (g PO4 eq/kg LLDPE) Eutrophication rd Party Environmental Report: No Significant Impact Expected Fossil-based PE Cane-based PE Eutrophication mostly from bagasse combustion No fertilizer runoff expected Page 17

18 Net Water Demand (L H2O/kg LLDPE) Net Water Demand Fossil-based PE Cane-based PE * studies have shown that the quantity of water to be extracted from the reservoir will not have any adverse effects on aquatic fauna or other water users. ERM *Worst case scenario. Actual water demand will be lower. No adverse effects on local water users. Page 18

19 Environmental Impact Study Environmental Impact Study by ERM Candidate site* evaluated in detail Eutrophication - No adverse effects on flora or fauna Water Demand - No adverse effects on local water users Cane-based PE is disadvantaged in these areas compared to Fossilbased PE, but no significant impacts are expected *Santa Vitória site evaluated. Final site to be determined. Page 19

20 Conclusions LCA for Cane-based PE conducted based on detailed design data Study critically reviewed according to ISO 14040/44 Significant Cane-based PE Advantages: Global Warming Potential Fossil Energy Demand Cane-based PE Tradeoffs: Land, Water, Eutrophication No Significant Local Impacts (Environmental Impact Report) Cradle-to-Gate Impacts dominated by Agricultural Operations Cane farming methods significantly influence results Page 20

21 Acknowledgement Dow Chemical Alberto Ulriksen Cane PE Marketing Team Dave Davies, Gustavo Botto, Ryan Johnson, Bob Goosen Project Engineering David Russell LCA Expert Group Santelisa Vale (Sugarcane/Ethanol Producers for Crystalsev) Valmir Barbosa Agricultural Management Reginaldo Aparecido Braga, Nalmir Moreira Junior Industrial Management Michigan Technological University Prof. David Shonnard (critical reviewer) Page 21

22 Thank You for your Attention! Shawn E. Hunter Dow LCA Expert Group

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