[PPT] - Life Cycle Assessment and Costing for Measuring Sustainability of PowerPoint Presentation

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Sustainable Coatings

EC European Coatings Conference, 18-19 June 2013 Düsseldorf

Life Cycle Assessment and Costing for Measuring Sustainability of Coatings

LCS Life Cycle Simulation GmbH www.lcslcs.de

Dr. Matthias Harsch, Julian Maruschke, Judith Schnaiter

LCS Life Cycle Simulation GmbH, Backnang, Germany www.lcslcs.de

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LCA and LCC for Measuring Sustainability

Overview

Sustainability – Introduction Challenges for Coatings Tools – LCA and LCC

LCS Life Cycle Simulation GmbH www.lcslcs.de

Application of LCA and LCC Outlook

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Intensity

Sustainability – Introduction

Characteristic Development of unsustainable Processes

LCS Life Cycle Simulation GmbH www.lcslcs.de

Time

Excessive increase – short maximum – strong decrease

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increasing dynamic

scarce resources demographic change climate change; energy consumption

megatrends

f

sustainability

Sustainability – Introduction

Challenges for a sustainable Future

LCS Life Cycle Simulation GmbH www.lcslcs.de

resources change fresh water shortage

sustainability

Knowledge management of increasing “dynaxity*”

*Dynaxity = Dynamics + Complexity; Source: megatrends of sustainability, Bundesministerium für Umwelt, Berlin, 2008

increasing complexity

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Viewing Angle

view into details

verall view

Sustainability – Introduction

LCS Life Cycle Simulation GmbH www.lcslcs.de

Both views are mandatory to evaluate sustainability

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Technosphere Ecosphere

Sustainability – Introduction

Interaction between Interaction between Technosphere Technosphere, Ecosphere and Society , Ecosphere and Society

evolution renewable resources non-renewable resources technical development application of technologies scarcities of materials (?)

Society

LCS Life Cycle Simulation GmbH www.lcslcs.de

Tools required to analyze this permanently changing interaction sustainability economy ecology social

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production sites worldwide technologies (state-of-the-art, LCS life cycle models technology strengths, weak points, potentials economy limits of profit-

bench Sustainability – Introduction

Knowledge Management - Part of LCS Services

LCS Life Cycle Simulation GmbH www.lcslcs.de

(state-of-the-art, innovations) work time model limits of profit- ability, cost drivers ecology resources, emissions

chmark

Understand (transparency) – rearrange – evaluate – implement

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Sustainability – Introduction

Sustainability in the Coating Industry

Coatings are generally sustainable: long-term protection saves resources1
By corrosion and decay arises in Germany an economic loss of 3.9%

(Western Europe: 3.5-4.2%) of the gross domestic product per year, equivalent to 100 billion € in 2012²

Sustainability is the driving force for new developments³

– reduction of energy consumption – raw materials, which allow a low content of volatile gases (VOC)

LCS Life Cycle Simulation GmbH www.lcslcs.de

– raw materials, which allow a low content of volatile gases (VOC)

Future properties by sustainable use of products like easy-to-clean or

scratch resistance³

Sources:1) Deutsches Lackinstitut. 2) Deutsches Lackinstitut 2013. Nachhaltigkeit par excellence. Lack im Gespräch o.J. (114): 1. 3) European Coatings, Show 2013.

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LCA and LCC for Measuring Sustainability

Overview

Sustainability – Introduction Challenges for Coatings Tools – LCA and LCC

LCS Life Cycle Simulation GmbH www.lcslcs.de

Application of LCA and LCC Outlook

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Challenges for Coatings

General technical performance sustainability economy ecology social

LCS Life Cycle Simulation GmbH www.lcslcs.de

Fullfilment of technical performance is required

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Challenges for Coatings

Life Cycle Perspective

End

f

Use Applic- Coating produc- Binders Solvents Pigments

… … … … … … … … … … … … … … … … … … … …

wable resources

LCS Life Cycle Simulation GmbH www.lcslcs.de

Cost, energy and material efficiency in each process step

f

life Use ation produc- tion Pigments Fillers Additives

… … … … … … … … … … … … … … … … … … … …

Non and renewa

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Challenges for Coatings

Life Cycle Modelling (LCM) – Build-up of Life Cycle into a parameterized Model

Results Results

LCS Life Cycle Simulation GmbH www.lcslcs.de

LCM enables to look forward or backward from each point of a life cycle

Results Results Results Results

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Challenges for Coatings

Life Cycle Perspective – Detail: Selection of Production Routes

Ethylen- glykol Bisphenol A Phenol Aceton Glycidyl- methacrylat Hydroxy- ethylmeth- acrylat Butyl- acrylat Hydroxy- ethylacrylat Methyl- methacrylat Methyldi- ethanol als Diamin Polyether als Polyol Polyester als Polyol Iso- cyanate Acetoncy- anhydrin Epichlor- hydrin Dicarbon- säure

Epoxidharz Acrylatharz Polyurethanharz

Styrol

Epoxy resin Acrylic resin Polyurethane resin

Products

LCS Life Cycle Simulation GmbH www.lcslcs.de

Life cycle perspective helps to find best solution

Ethylen-

xid

Ethylen Pyrolyse- benzin Propylen Chlor Ammoniak Synthese- gas CO Cumol Calcium- hydroxid Ethyl- benzol Meth- acryl- säure Allyl- chlorid Acryl- säure Methan Butanol Propylen-

xid

Steinsalz Erdöl Erdgas

Acrolein Benzol Xylol

Resources

Sodium chloride Crude oil Natural gas

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Challenges for Coatings

Life Cycle Perspective – Detail: Material Efficiency at Application

purchased coat for

cleaning losses coat residue

verspray,

solids on skids 50% solids

LCS Life Cycle Simulation GmbH www.lcslcs.de

purchased coat coat for application used coat

n product often <20%

exhaust air drying oven exhaust air spray booth cleaning losses coat residue 50 50% solvents

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Challenges for Coatings

Investment and Development of Operating Costs potential 2 millions/a operating costs

30 40 50 60 in mill. EURO

44 millions in 20 years

Example: medium-sized painting plant

LCS Life Cycle Simulation GmbH www.lcslcs.de

Long plant operation time consider the life cycle costs

20 Plant operation time in years

4 millions investment

10 20 5 10 15 Total costs in

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Challenges for Coatings

Procedure of Investment Decisions

bid solicitation functional specification document

classical procedure

ptimized procedure

total investment

plant construction start of production placing of an order plant

ptimization

plant conversion

LCS Life Cycle Simulation GmbH www.lcslcs.de

Comprehensive preparation for long term investments is profitable

systematic technology selection

verview of

promising alternatives

bid solicitation technology simulation

ptimized

concept

identification

f strengths,

weaknesses and potential

functional specification document

ptimized procedure

plant construction start of production placing of an order plant

ptimization

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LCA and LCC for Measuring Sustainability

Overview

Sustainability – Introduction Challenges for Coatings Tools – LCA and LCC

LCS Life Cycle Simulation GmbH www.lcslcs.de

Application of LCA and LCC Outlook

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Life Cycle Assessment (ISO Standards 14040 & 14044)

Tools – LCA and LCC

goal/ scope definition inventory analysis LCA framework production use preparation

LCS Life Cycle Simulation GmbH www.lcslcs.de

Measuring ecological sustainability

analysis impact assessment recycling resources emissions to environment renewable resources carbon cycle

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Life Cycle Costing

PRODUCT Life Cycle Costing

static dynamic

different system boundaries

Ressources Extraction Production Use Disposal/ Recycling

life cycle cost material cost

manufacturing cost

total production cost

Tools – LCA and LCC

LCS Life Cycle Simulation GmbH www.lcslcs.de

Measuring economical sustainability

CAPITAL GOODS Capital Budgeting

different system boundaries

Purchase Operation Abandon- ment

Total Cost of Ownership static dynamic investment cost

peration and maintenance cost

abandonment cost

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Primary Energy Demand and Material Costs

Tools – LCA and LCC

6 8 10 12 is in € pro kg

Max Min

energy in MJ per kg 300 400 500

more than 700 MJ more than 20 €

„Exotic“ products can have even higher values. sts in € per kg

LCS Life Cycle Simulation GmbH www.lcslcs.de

2 4

BM/ HÄ (PE) BM/ HÄ (Ko) Lösemittel (PE) Lösemittel (Ko) Pigmente (PE) Pigmente (Ko) Additive (PE) Additive (Ko) Füllstoffe (PE) Füllstoffe (Ko)

Preis

Primary ene 100 200

Costs

B/ H (PE) B/ H (Co) Solvent (PE) Solvent (Co) Pigment (Co) Pigment (PE) Additive (PE) Additive (Co) Filler (Co) Filler (PE)

Economy and ecology provide similar messages

B = Binder H = Hardener Co = Costs PE = Primary energy

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LCA and LCC for Measuring Sustainability

Overview

Sustainability – Introduction Challenges for Coatings Tools – LCA and LCC

LCS Life Cycle Simulation GmbH www.lcslcs.de

Application of LCA and LCC Outlook

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Modeling of coating process over life cycle
One layer coating process for plastic cabinets (pretreatment not shown)
2 shift production, 4.250 h/a, location Berlin (climate data)
Solvent borne topcoat (50% solids), layer thickness 40 µm, transfer

efficiency 20% (manual)

Application of LCA and LCC

Definition of Coating Process (Starting Point)

ly

LCS Life Cycle Simulation GmbH www.lcslcs.de

Spray booth Flash

ff

Oven

Cooling zone

Periphery (hall, conveyor, VOC abatement) Material and energy supply Resources Use (not investigated) End-of-life Emissions

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Application of LCA and LCC

Coating Process (Starting Point) – LCA Coating Process

LCS Life Cycle Simulation GmbH www.lcslcs.de PE = Primary energy (cradle to gate), direct = direct energy input to specific process step

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Application of LCA and LCC

Normalization of Resources and Emissions

Yearly impacts EU 28 countries Impacts Life cycle of coating process

LCS Life Cycle Simulation GmbH www.lcslcs.de

Normalisation: Cv = (Impacts Life Cycle of materials) / (Yearly impacts EU 28 countries) Characteristic values (Cv) without unit for ADP, GWP, POCP, AP, EP to show relevancy of impact categories

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2,5E-02 3,0E-02 3,5E-02 4,0E-02

5+3 referenz factors

Application of LCA and LCC

Coating Process (Starting Point) – Normalization of LCA Results

LCS Life Cycle Simulation GmbH www.lcslcs.de

0,0E+00 5,0E-03 1,0E-02 1,5E-02 2,0E-02 ADP GWP POCP AP EP

Normalization to EU-25+

ADP = abiotic resource depletion; GWP = green house warming potential (carbon footprint); POCP = photochemical oxidants creation potential ; AP = acidification potential; EP = eutrophication potential

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Application of LCA and LCC

Coating Process (Starting Point) – LCC Coating Process

LCS Life Cycle Simulation GmbH www.lcslcs.de

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27 0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

GWP - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Primary energy - life cycle

Application of LCA and LCC

Coating Process (Starting Point) – LCA and LCC Coating Process

LCS Life Cycle Simulation GmbH www.lcslcs.de

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Costs - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

POCP - life cycle

start step 1 step 2 step 3 step 4 start step 1 step 2 step 3 step 4

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28 0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

GWP - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Primary energy - life cycle

Application of LCA and LCC

Coating process (starting point) – LCA and LCC coating process (Step 1)

LCS Life Cycle Simulation GmbH www.lcslcs.de

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Costs - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

POCP - life cycle

start step 1 step 2 step 3 step 4 start step 1 step 2 step 3 step 4

Step 1: implementation of VOC abatement (fullfilment of VOC directive)

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29 0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

GWP - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Primary energy - life cycle

Application of LCA and LCC

Coating Process (Starting Point) – LCA and LCC Coating Process (Step 2)

LCS Life Cycle Simulation GmbH www.lcslcs.de

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Costs - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

POCP - life cycle

start step 1 step 2 step 3 step 4 start step 1 step 2 step 3 step 4

Step 2: implementation of water borne coating (fullfilment of VOC directive)

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30 0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

GWP - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Primary energy - life cycle

Application of LCA and LCC

Coating Process (Starting Point) – LCA and LCC Coating Process (Step 3)

LCS Life Cycle Simulation GmbH www.lcslcs.de

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Costs - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

POCP - life cycle

start step 1 step 2 step 3 step 4 start step 1 step 2 step 3 step 4

Step 3: improvement of material and energy efficiency

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Application of LCA and LCC

Coating Process (Starting Point) – LCA and LCC Coating Process (Step 4)

Step 4: transfer of research results from bmbf-project ENSIKOM high material efficiency by recycling of solids and solvents high energy efficiency (compact process + UV curing), no gas use

LCS Life Cycle Simulation GmbH www.lcslcs.de

www.r-zwei-innovation.de/de/673.php

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32 0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

GWP - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Primary energy - life cycle

Application of LCA and LCC

Coating Process (Starting Point) – LCA and LCC Coating Process (Step 4)

LCS Life Cycle Simulation GmbH www.lcslcs.de

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

Costs - life cycle

0% 20% 40% 60% 80% 100% 120% start step 1 step 2 step 3 step 4

POCP - life cycle

start step 1 step 2 step 3 step 4 start step 1 step 2 step 3 step 4

Step 4: implementation of new developed coating process

?

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Application of LCA and LCC

Life Cycle Optimization Potential - Estimation

271 tons crude oil equivalents per year 10.4 oil trucks á 26t net load per year

boundary conditions: 2-shift production process savings: difference starting point to step 4

LCS Life Cycle Simulation GmbH www.lcslcs.de

10.4 oil trucks á 26t net load per year 670 tons CO2 equivalents per year 5.5 Mio. km at 120g CO2 per km In addition: reduction of 61.2 tons of VOC emissions per year

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LCA and LCC for Measuring Sustainability

Overview

Sustainability – Introduction Challenges for Coatings Tools – LCA and LCC

LCS Life Cycle Simulation GmbH www.lcslcs.de

Application of LCA and LCC Outlook

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Outlook

Sustainable development needs

Appreciation for life and nature
Awareness of interaction between technosphere and ecosphere under

societal boundary conditions

Different viewing angles, i.e. life cycle perspective versus view into details

LCS Life Cycle Simulation GmbH www.lcslcs.de

Different viewing angles, i.e. life cycle perspective versus view into details

We have the consciousness and skills to create our future sustainable Let Us Do It

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Contact

LCS Life Cycle Simulation GmbH

Your contacts:

Dr.-Ing. Matthias Harsch Managing director

LCS Life Cycle Simulation GmbH www.lcslcs.de

Managing director Email: matthias.harsch@lcslcs.de Dipl.-Ing. Julian Maruschke Project manager Email: julian.maruschke@lcslcs.de Dipl.-Ing. Judith Schnaiter Project manager Email: judith.schnaiter@lcslcs.de