Life Cycle Assessment of Process Gas Boiler System Larsen & Toubro 8 th November, 2013
Larsen & Toubro Larsen & Toubro is a USD 14 Billion technology, engineering, construction, manufacturing and financial services conglomerate with global operations
Powai Campus Founded in 1958 Plate Cutting Heavy Engineering - Powai Fabrication Welding Machining 3
Plant Profile Heavy Engineering Design & Engineering System design, thermal / mechanical design, material and welding engineering Fabrication Max Equipment Size: Weight 400 Ton, Length - 47m, Diameter 6m Destructive & Non Destructive Testing Manufacturing Heavy fabrication and machining test, site service 200 mm thickness acetylene and plasma cutting 1000 ton hydraulic press 25000 ton rolling machine (hot & cold bending) Welding SAW, TIG, MIG, SMAW, ESSC, FCAW processes, automatic and robotic welding Machining CNC Horizontal and Vertical Boring, Turning, Drilling, Deep Hole Drilling Technology Centre Process design, radar and transmitters, ship stabilizer, launcher designs and analysis Commissioning & Site Support 4
L&T Product Responsibility
Background of LCA Study To promote and champion conservation of natural resources in Indian industry without compromising on high and accelerated growth" Sr. No. Parameters Weightages (Points) 1 Energy Efficiency 150 2 Water Conservation 100 3 Renewable Energy 100 4 GHG Emission Reduction 100 5 Material Conservation, Recycling & Recyclables 100 6 Waste Management 100 7 Green Supply Chain 100 8 Product Stewardship 75 9 Life Cycle Assessment 75 10 Others (Ventilation, Site Selection & Innovation) 100
Objective of LCA Study The main objective of the study is to evaluate the cradle-to-gate lifecycle i.e. from raw material acquisition, material production, transport, assembly and fabrication data for Process Gas Boiler system in order to calculate life cycle inventories ( Life Cycle Inventory or LCI ). To fulfil the requirements of GreenCo Rating system
Life Cycle Assessment L&T Compilation and evaluation of the inputs, outputs and the potential environmental impacts of a product system throughout its life cycle ISO 14040/44 Target To conduct the LCA of process gas boiler assembly (1 No. 36 TPH capacity). This product has been chosen as the Company has developed an expertise in the manufacturing of the same over several years and it represents a significant portion (> 25 %) of the Company s order book (Powai West) for FY 2012-13. The Company expects to receive similar orders in future.
LCA study framework Scope To evaluate various environmental impacts of all activities associated with fabrication of a process gas boiler assembly System Boundary The LCA of the process gas boiler assembly covers the cradle to gate approach, consisting of raw materials transport, manufacturing, assembling, energy and auxiliary materials consumption till dispatch Functional Unit One Process Gas - Waste Heat Recovery Boiler assembly having three subassemblies as steam drum, rise and down comer pipe and process gas boiler and capacity of 36TPH of steam generation.
LCA study - Flow chart Goal and Scope Definition Data Collection and Data Quality Check LCA System Modelling (using GaBi Software) LCI and LCIA calculations and comparison if any Final Report Standards followed - ISO 14040/44 Software used for modeling - GaBi 6 developed by PE International AG.
Life Cycle stages Raw material acquisition Material processing Production Use and maintenance Natural Resources Air Emissions Water Effluents Solid Waste Cradle to gate boundary End-of-life
System Boundaries The Life Cycle Analysis of one process gas boiler covers the cradle to gate approach, consisting of raw materials transport, manufacturing, fabrication, assembly, energy and auxiliary material consumption. Life Cycle stages Life Cycle sub-stages Definitions Materials & energy production Upstream Transport Assembly Primary raw materials Raw material receipt Sub components Formation Energy, fuel and raw materials used in the process of formation of the primary sub components production Transport of the raw materials for primary production of the assembly Diesel, electricity and lubricating oil consumption during inhouse assembly of the boiler production and testing In-house locomotive In-house transport of various materials
Process Gas boiler breakup Process gas boiler assembly Riser & Down comer piping Steam Drum General Assembly
Process Gas Boiler System 1 2 LH-RH Dishend fabrication Shell fabrication 3 Tube sheet fabrication 4 Nozzle fabrication 5 External fabrication 6 Internal fabrication 7 Post Weld Heat Treatment 8 Hydro testing 10 9 Refractory Dispatch
Data Collection & Assumptions Data was collected from various functions on bill of materials, fuel, energy, transportation which further were imported to the GaBi software for analysis. Consolidated primary data for various machining and fabrication processes are considered wherever part specific data was not available The environmental profiles of various materials used in the fabrication of boiler are sourced from GaBi 6 Professional 2012 databases wherein close substitutes for materials are considered wherever the dataset was not available Upstream transportation data has been considered in the assessment.
LCA Environmental Impact S.N 1 2 4 3 5 Parameters Acidification Potential (AP) [kgso 2 - Equiv.] Global Warming Potential (GWP100 years) [kgco 2 - Equiv.] Ozone Layer Depletion Potential (ODP, steady state) [kg R11-Equiv.] Photochemical. Ozone Creation Potential (POCP) [kg Ethene-Equiv.] Primary energy demand from ren. and non-ren. Resources (net cal. value) [MJ] 6 Total freshwater consumption (including rainwater) [cu.m] Process gas Boiler Assembly (1) Riser & Down comer piping (2) Steam Drum General Assembly (3) Waste-Heat Recovery Boiler Assembly (1+2+3) 447.93 386.37 316.5 1,150.77 1,02,115.36 74,507.01 91,644.3 2,68,266.64 0.00 0.00 0.00 0.00 38.53 28.57 38.15 105.26 14,50,834.09 11,19,062.71 12,37,340.16 38,07,236.97 54,093.7 20,238.1 38,931.2 1,13,263.0
Observations Global Warming Potential (2,68,266 kg CO 2 -Equiv.) Primary energy demand (38,07,236 MJ) 35% 35% Process gas Boiler Assembly Riser & Down comer piping 33% 34% Process gas Boiler Assembly Riser & Down comer piping 30% Steam Drum General Assembly 33% Steam Drum General Assembly
Observations Total freshwater consumption (1,13,263 cu.m) 4% 19% Material consumption (1,03,956 kg) 0.50% 0.00 Carbon Steel High Dense Alumina Low Alloy steel 35% 18% 48% Process gas Boiler Assembly Riser & Down comer piping Steam Drum General Assembly 76% Stainless Steel High tensile bolting
Observations Acidification Potential (AP) assembly wise %[kg SO 2 -Equiv.] 1150 Kg Photochem. Ozone Creation Potential break-up % by assembilies (POCP) [kg Ethene- Equiv.] 105 Kg 37% 34% Process gas Boiler Assembly 27% 37% Process gas Boiler Assembly Riser & Down comer piping 29% Riser & Down comer piping Steam Drum General Assembly 35% Steam Drum General Assembly
L&T- LCA study results S.No Parameters Activities outside L&T campus Activities inside L&T campus Total 1 Acidification Potential (AP) [kgso 2 - Equiv.] 936.47 (81.38%) 214.3 (18.62%) 1,150.77 2 Global Warming Potential (GWP100 years) [kgco 2 -Equiv.] 1,42,518.01 (53.13%) 1,25,748.63 (46.87%) 2,68,266.64 3 Ozone Layer Depletion Potential (ODP, steady state) [kg R11-Equiv.] 0.00 0.00 0.00 4 Photochemical. Ozone Creation Potential (POCP) [kg Ethene-Equiv.] 80.31 (76.30%) 24.95 (23.70%) 105.26 5 Primary energy demand from ren. and non-ren. Resources (net cal. value) [MJ] 20,47,260.62 (53.78%) 17,59,976.35 (46.22%) 38,07,236.97 6 Total freshwater consumption (including rainwater) [cu.m] 1,13,171.29 (99.92%) 91.71 (0.08%) 1,13,263.0
Recommendations 1. Reduce material consumption by 5%. 2. Material substitution with less resource intensive materials 3. Material substitution with locally sourced materials 4. Increase renewable energy component 5. Reduce absolute energy consumption by 5% 6. Decrease in natural gas consumption by 5%
Reduction in weight of material & Environmental Impact If weight of material is reduced by 5%, the key environmental parameters like GWP, Primary energy demand & total fresh water consumption for the process gas boiler system reduces as mentioned in below table: S.No. 1 Parameters Reduction Global Warming Potential (GWP100 years) [kgco 2 -Equiv.] If Weight of material is reduced by 5% 12,199 (4.55%) 2 Reduction in Primary energy demand from ren. and non-ren. resources(net cal. value) [MJ] 1,69,658 (4.46%) 3 Reduction Total freshwater consumption(in-clouding rainwater) [cu.m.] 5,663 (4.99%)
Material substitution Replacement of Steel by: Advanced high strength plates Light weight plates Sourcing IS grade materials Scrap: Substitution with scrap metal in similar line downstream / upstream
Local sourcing of materials Consider the public private partnership with locally present steel companies like Steel Authority of India Ltd. (Bhilai), Essar Steel for developing high strength & light weight plates. Sourcing from L&T Forge shop, Hazira.
Increase in renewable energy sources At present, the Powai West campus is sourcing approx. 75% of total energy demand from renewable sources. Further, if the percentage of renewable energy over the entire lifecycle is increased to 90%, the reduction in environmental impacts is mentioned in table : S.No. Parameters 90% Renewable Energy 1 Reduction in Global Warming Potential (GWP100 years) [kgco 2 - Equiv.] 16,025 (5.97%) 2 Reduction in Primary energy demand from ren. and non-ren. resources(net cal. value) [MJ] 1,60,297 (4.21%) 3 Reduction in Total freshwater consumption(in-clouding rainwater) [cu.m.] 68,913 (60.8%)
Reducing absolute energy consumption by 5% If absolute energy consumption is reduced by 5% the key environmental parameters like GWP, Primary energy demand & total fresh water consumption in process gas boiler system reduces as mentioned in below table: S.No. 1 Parameters Reduction in Global Warming Potential (GWP100 years) [kgco 2 -Equiv.] If absolute energy consumption is reduced by 5% 1,201 (0.44%) 2 Reduction in Primary energy demand from ren. and non-ren. resources(net cal. value) [MJ] 12,016 (0.33%) 3 Reduction in Total freshwater consumption(in-clouding rainwater) [cu.m.] 5,165 (4.56%)
Reducing Natural Gas consumption by 5% If Natural Gas (NG) consumption is reduced by 5% the key environmental parameters like GWP, Primary energy demand & total fresh water consumption reduces by as mentioned in below table: S.No. 1 2 Parameters Reduction in Global Warming Potential (GWP100 years) [kgco 2 -Equiv.] Reduction in Primary energy demand from ren. and non-ren. resources(net cal. value) [MJ] If Natural Gas consumption is reduced by 5% 3,741.5 (1.39%) 63,796 (1.67%) 3 Reduction in Total freshwater consumption(in-clouding rainwater) [cu.m.] 1.5 (~0.01%)
Recommendations Reduction in parameters If energy consumption reduces by 5% If Natural Gas consumption reduced by 5% Sourcing of Wind power (90 %) If weight of material is reduced by 5% External L&T In-house External L&T In-house External L&T In-house Cradle to Gate Acidification Potential (AP) [kg SO 2 - Equiv.] Global Warming Potential (GWP 100 years) [tons CO 2 -Equiv.] Primary energy demand (net cal. value) [MJ] 0.81 0.19 8.1 1.9 6.48 1.52 58 (5.04%) 638.09 562.91 1,987.59 1,753.91 8,509.27 7,510.92 12199 (4.55%) 6,462.20 5,553.8 34,309.49 29,486.51 86,207.73 74,089.27 169658 (4.46%) Total freshwater consumption [cu.m] 5,160.87 4.13 1,479.04 1.18 68,857.86 55.13 5663.2 (5.0%)
Benefits of LCA Study Demonstrates the ecological performance of the product Supports the decision-making during product development Helps the Company to revisit and improve its own benchmark Provides a business connect
Way forward Gate to grave (end-of-life) LCA of more products Development of LCA framework Environmental Product Declaration / Eco-labeling
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