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

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

1 Sustainable Coatings EC European Coatings Conference, 18-19 June 2013 Dsseldorf Life Cycle Assessment and Costing for Measuring Sustainability of Coatings Dr. Matthias Harsch, Julian Maruschke, Judith Schnaiter LCS Life Cycle Simulation


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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- meth- acrylat 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