Application of LCA & EcoDesign in Eco-Products Development: Case Study for Eco-compressor

Transcription

1 Application of LCA & EcoDesign in Eco-Products Development: Case Study for Eco-compressor by 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 Technology 2 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 Overview 2. Introduction to LCA 3. Introduction to EcoDesign 4. Pilot Project: Eco-compressor 2

3 1.Environment Legislation Overview; EU Legislation Source: EGG Materials 3

4 Japan Legislation (all laws below are already enforced) Basic Environment Law Basic Law for Establishing the Recycling-based Society Waste Disposal and Public Cleaning Law Law for the Promotion of the Effective Utilization of Resources (Promote 3Rs) (2001) Recycling laws for individual fields 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 Law on Promoting Green Purchasing (2001) 4 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) 5

6 Solution Need to go Green GREEN COMPETITIVENESS Tools: CT + LCA + EcoDesign 6

7 2. Introduction to LCA Product Life Cycle From Cradle to Grave Impacts on Human health Ecosystems Resources 7

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) 8

9 Road Map - ISO Evaluation & Auditing Tools Environmental Performance Evaluation (EPE) ISO guidelines Environmental Auditing (EA) general principles audit procedures qualification criteria for environmental auditors Management Systems ISO (EMS) general guidelines on principles, systems & supporting techniques ISO (EMS) specification with guidance for use Product-Oriented Support Tools Life Cycle Assessment (LCA) general principles & practices life cycle inventory analysis life cycle impact assessment life cycle improvement assessment Environmental Labelling (EL) basic principles for all environmental labelling terms & definitions symbols testing & verification guiding principles, practices & criteria for certification programs 9

10 ISO Life Cycle Assessment, Principles and Framework Life cycle assessment framework Goal and scope definition Inventory analysis Impact assessment Interpretation Direct applications: - Product development and improvement - Strategic planning - Public policy making - Marketing -Other Source: ISO (ISO, 1997) 10

11 Life Cycle Inventory Analysis (LCI) Foreground Data Manufacturing Use Disposal Materials Mining Electricity Fuels Background Data Ref: Dr.INABA, AIST 11

12 Utilization of LCA Voluntary Improvement Design for Environment (DfE) Marketing Recycling Design Process Improvement Appealing (Public Relations) Information Disclosure Environmental Management System Environmental Administration (Support for recycling, etc) Reflection to Social/Economic Systems LCA Green Procurement Environmental Education Lifestyle Review Environmental Reports Environmental Labeling Consumption Activity 12 Ref: Ishizaka, Nagano prefecture

13 3. Introduction to EcoDesign Product Design is a critical determinant of a manufacturer s competitiveness National Research Council, USA: estimates that 70% or more of the costs of product development, manufacture and use are determined during the initial design stages Bad design leads to inefficient use of resources and excessive waste Trade Barriers using environmental aspects (packaging / hazardous substances / product recyclability etc.) 13

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. 14

15 What can be achieved with EcoDesign? Considerable reduction in environmental load (e.g., 30-50% or higher) often feasible in short term Saving of materials and energy Reduction in waste Innovative product design Considerable 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 15

16 UNEP Eco-Strategies Wheel Optimization of end-of-life system Reuse of product Remanufacturing/refurbishing Recycling of materials Clean incineration Optimization of initial life-time Reliability and durability Easy maintenance and repair Modular product structure Classic design User taking care of product Reduction of the environmental impact in the user stage Low energy consumption Clean energy source Few consumables needed during use Clean consumables during use No energy/auxiliary material use 4 0 New Concept Development Dematerialisation Shared use of the product Integration of functions Functional optimization of product (components) - + Efficient distribution system Less/clean packaging Efficient transport mode Efficient logistics 3 1 Selection of low-impact materials Non-hazardous materials Non-exhaustable materials Low energy content materials Recycled materials Recyclable materials 2 Reduction of material Reduction in weight Reduction in (transport) volume Optimization of production techniques Alternative production techniques Fewer production processes Low/clean energy consumption Low generation of waste Few/clean production consumables Priorities for the new product Existing product 16

17 EcoDesign Process Flow EcoDesign Tools QFDE DFE Checklist Target Product / Parts Analysis and Evaluation of the Present Design Product Concept Making Conceptual Design Qualitative Design Review Detailed Design EcoDesign Phases Phase I Planning Phase II Analysis & Generation Phase III Design & Development LCA Eco-Indicator Quantitative (Final) Design Review Approval Phase IV Verifying & Approval 17

18 Energy Consumption of Various Home Appliances Electricity consumption in residential sector 4% 2% 7% 5% 19% 17% 46% Air conditioner Re frigerator Rice cooker Fans Washing Machine Water boiler Other Source: Conclusion Report (2000) of Consulting Assignment-Load Research Program, EGAT Source: EGAT Public Company Ltd. (2000) 18

19 Environmental impact of compressor usage Electricity Consumption Electricity Consumption of Refrigerator is 20% of residential sector Acidification & Green House Effect from Energy Consumption CFC Substance Emission Ozone depletion Solid waste Steel scrap, Slag 19

20 Production Capacity of each type compressor in Thailand 4,000,000 3,500,000 Capacity (unit/ year) 3,000,000 2,500,000 2,000,000 1,500,000 1,000, , Year Source: Siam Compressor Industry Co., Ltd. (2003) Rotary Com. Scroll Com. Reciprocating Com. 20

21 Refrigerator & compressor production capacity in Thailand 7,000,000 6,000,000 Production (Units/year) 5,000,000 4,000,000 3,000,000 2,000,000 Compressor Refrigerator 1,000, Year 21

22 Export Value of Refrigerator in Thailand 18,000 16,000 Export value (million baht/year) 14,000 12,000 10,000 8,000 6,000 4,000 Domestic refrigerator Comercial refrigerator 2, Year 22

23 4. Pilot Project: Eco-compressor Collaborative project between government and industry strategic partner Signing an cooperative agreement between MTEC and SUE (KPC) on August 27, 2003 As a pilot project of the NETH program of GMTAP 23

24 Demonstration Project to Produce Prototype of a more Environmental Friendly Compressor Cast iron parts Redesign parts 24

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) 25

26 Current Situation Eco-Design Part o JODC-Expert dispatch: Mr.Akira Arai, visit 3 times (7-11 June 04, Nov 04, 7-11 Feb 05) o Review design & detail design of the compressor parts o 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 test o Mechanical testing of the connecting rod 26

27 Mr.Akira Arai (3 Visits): Advice on Compressor Design 27

28 Mold Making & Eco-Parts 28

29 Performance Test of Compressor Type Cooling capacity (BTU/hr) COP (W/W) Noise (db A) Current model New model I (connecting rod + piston + crankcase (bush) as sinter)

30 LCA Part Goal to 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 unit Refrigerated temperature at 5 o C for 10 years with an ambient temperature at 32 o C 30

31 Simplified Process Tree for a Compressor s Life-Cycle cast iron PE Cu wire silicon steel Al ingot steel sheet small parts Cu tube machining injection moulding cutting cutting injection stamping forming forming forming washing suction assembly stator assembly rotor assembly shell assembly main assembly painting/ packing use in refrigerator electricity disposal 31

32 Production of Compressor Hot Rolled Sheet Cold Rolled Sheet Silicon Steel Cast Iron Steel Aluminium Copper Manufacturing Plant Plastics Compressor Paints Parts Supplier 32

33 Inventory Data of the Compressor Materials/Resources Steel xxx kg Cast Iron xxx kg Copper xxx kg Al xxx kg Plastic xxx kg Paint xxx kg BA oil xxx L Gear Oil xxx L NUTO Oil xxx L Telluse Oil xxx L Cutta Oil xxx L Macron Oil xxx L Lubricant xxx kg Trichloroethylene xxx L Nano water xxx L Water xxx L Energy Uses Electricity xxx kwh LPG xxx m 3 Fuel Oil xxx L Compressor Factory Solid Waste Steel scrap xxx kg Cast iron waste xxx kg Emission to Air CO xxx kg CO 2 xxx kg NO X xxx kg SO X xxx kg VOC xxx kg H3PO4 xxx kg Mn xxx kg Ethylene Glycol xxx kg Compressor Emission to Water ph 7.4 BOD xxx kg COD xxx kg SS xxx kg Grease & Oil xxx kg Waste water xxx L 33

34 Main Materials of Compressor PM part 0.29% Copper 10.24% Plastic 0.63% Al 2.21% Paint 0.21% Others 0.24% Cast iron 14.25% Steel 71.93% 34

35 Life Cycle Impact Assessment of Compressor Single score (Pt) Materials Production Disposal summer smog winter smog carcinogens heavy metals eutrophication acidification ozone layer greenhouse

36 Life Cycle Impact Assessment: main component Single score (Pt) summer smog winter smog carcinogens heavy metals eutrophication acidification ozone layer greenhouse Stator core Magnet wire Rotor core Cast iron parts Shell Al ingot Crank shaft 36

37 Life Cycle Impact Assessment based on Categories % Global warmi Ozone Acidific depletion ation Eutrop hicati Photoc hemi Ecotox i city Ecotoxi city Ec otoxi city soil Human toxicit y Human toxicit y Human toxicit y Bulk waste Hazard ous 0 Radioa ctive Slags/a shes Resour ces Stator Assy OP1 Cylinder Assy Plate Support Assy Valve Head Assy Spring Assy Disch pipe Assy Suction Muffler Assy Shell A Assy(Alkaline) Shell B Assy(Alkaline) Compressor Assy Dry of Oven CS Welding Leak Test Pre Treatment ED Painting ED Oven N2 Charg(Fianl Line) Analyzing 1 p assembly 'Main Process Compressor'; Method: EDIP/UMIP 96 / EDIP World/Dk / characterization 37

38 Conclusions This Eco Compressor project is the first formal LCA-EcoDesign combination project in Thailand It is still a learning RD&E process between KPC+MTEC with a technical support from Japan through GPP The final result of this project is expected to be in the 3 rd quarter of

39 ACKNOWLEDGEMENT The technical support from Japanese Government through Green Partnership Plan (GPP) is acknowledged Dr. Thumrongrut Mungcharoen Cleaner Technology Advancement Program (CTAP) National Metal and Materials Technology Center (MTEC) National Science and Technology Development Agency Tel: (662) ext. 434 Fax: (662)