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”
2
Contents
1. Environment Legislations Overview
2. Introduction to LCA
3. Introduction to EcoDesign
3
Source: EGG 2004+ Materials
4
Law for the Promotion of the Effective
Utilization of Resources (Promote
“
3Rs) (2001)
Basic Environment Law
Waste Disposal and Public Cleaning Law
Law on Promoting Green Purchasing (2001)
Basic Law for Establishing the Recycling-based Society
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
Recycling laws
for individual
fields
Japan Legislation
(all laws below are already enforced)
5
Other Countries
z
China: WEEE/RoHS (Aug 2006)
z
USA: California; EE Recycle Law & RoHS
(enforce together with EU)
Hawaii; Ban PBDE (Jan 2006)
6
Solution
Need to go
“
Green
”
GREEN COMPETITIVENESS
Tools:
CT + LCA + EcoDesign
7
Product Life Cycle
“
From Cradle to Grave
”
Impacts on
•
Human health
•
Ecosystems
•
Resources
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
9
Road Map - ISO 14000
Management
Systems
ISO 14004 (EMS)
general guidelines
on principles, systems
& supporting
techniques
ISO 14001 (EMS)
specification with
guidance for use
Evaluation &
Auditing Tools
Environmental
Performance
Evaluation (EPE)
ISO 14031 guidelines
Environmental
Auditing (EA)
14010 general principles
14011-1 audit procedures
14012 qualification criteria
for environmental
auditors
Product-Oriented
Support Tools
Life Cycle Assessment (LCA)
14041 general principles &
practices
14042 life cycle inventory analysis
14043 life cycle impact assessment
14044 life cycle improvement
assessment
Environmental Labelling (EL)
14020 basic principles for all
environmental labelling
14021 terms & definitions
14022 symbols
14023 testing & verification
14024 guiding principles, practices
& criteria for certification
10
ISO 14040 Life Cycle Assessment,
Principles and Framework
Life cycle assessment framework
Goal and scope
definition
Inventory
analysis
Impact
assessment
Inter-pretation
Direct applications:
- Product development
and improvement
- Strategic planning
- Public policy making
- Marketing
- Other
11
Foreground Data
Materials
Electricity
Fuels
Manufacturing
Use
Disposal
Mining
Background Data
Life Cycle Inventory Analysis (LCI)
12
Utilization of LCA
Voluntary
Improvement
Marketing
Reflection to
Social/Economic
Systems
Consumption
Activity
Design for
Environment (DfE)
Appealing
(Public Relations)
Environmental Reports
Environmental Labeling
Environmental
Education
Lifestyle Review
Green
Procurement
Environmental
Administration
(Support for
recycling, etc)
Information Disclosure
Environmental
Management System
Recycling Design
Process Improvement
LCA
13
3. Introduction to EcoDesign
z
Product Design is a critical determinant of a
manufacturer’s competitiveness
z
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
z
Bad design leads to inefficient use of resources
and excessive waste
z
Trade Barriers using environmental aspects
(
packaging
/
hazardous substances
/
product
recyclability etc
.)
14
What is EcoDesign?
z
EcoDesign is a design approach that leads to
a profitable balance between ecological and
economical requirements when developing
products.
z
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.
15
What can be achieved with EcoDesign?
z
Considerable reduction in environmental load
(e.g., 30-50% or higher) – often feasible in short term
z
Saving of materials and energy
z
Reduction in waste
z
Innovative product design
z
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
16
UNEP Eco-Strategies Wheel
1
Selection of low-impact materials• •Non-hazardous materials
•Non-exhaustable materials
•Low energy content materials
•Recycled materials
•Recyclable materials
0
•
New Concept Development
•Dematerialisation
•Shared use of the product
•Integration of functions
•Functional optimization of product (components)
2
Reduction of material
•Reduction in weight
•Reduction in (transport) volume
3
Optimization of production techniques
•Alternative production techniques
•Fewer production processes
•Low/clean energy consumption
•Low generation of waste
•Few/clean production consumables
4
Efficient distribution system
• •Less/clean packaging
•Efficient transport mode
•Efficient logistics
5
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
6
Optimization of initial life-time•
•Reliability and durability
•Easy maintenance and repair
•Modular product structure
•Classic design
•User taking care of product
7
Optimization of end-of-life system
•Reuse of product •Remanufacturing/refurbishing •Recycling of materials •Clean incineration
+
-
+
-Existing product
17
EcoDesign Process Flow
Detailed Design
Approval
Quantitative (Final) Design Review
Target Product / Parts
Analysis and Evaluation of the Present
Design
Conceptual Design
Phase I
Planning
Phase II
Analysis &
Generation
Phase III
Design &
Development
Phase IV
Verifying
& Approval
LCA
Eco-Indicator
QFDE
DFE
Checklist
EcoDesign Tools
EcoDesign Phases
Qualitative Design Review
Product Concept Making
18
17%
5%
7%
19%
2%
4%
46%
Air conditioner
Refrigerator
Rice cooker
Fans
Washing Machine
Water boiler
Other
Source: Conclusion Report (2000) of “Consulting Assignment-Load Research Program”, EGAT
Electricity consumption in residential sector
Source: EGAT Public Company Ltd. (2000)
19
Environmental impact of compressor usage
z
Electricity Consumption
z
Electricity Consumption of
Refrigerator is 20% of
residential sector
z
Acidification & Green House
Effect from Energy
Consumption
z
Solid waste
z
Steel scrap, Slag
z
CFC Substance Emission
20
0
500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
2000
2001
2002
2003
Year
C
a
paci
ty
(
uni
t/
year
)
Rotary Com.
Scroll Com.
Reciprocating Com.
Production Capacity of each type
compressor in Thailand
21
Refrigerator & compressor
production capacity in Thailand
0 1,000,000 2,000,000 3,000,000 4,000,000 5,000,000 6,000,000 7,000,000 1999 2000 2001 2002 Year P rod uc ti on ( U ni ts /y ea r) Compressor Refrigerator
22
Export Value of Refrigerator in
Thailand
-2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 1998 1999 2000 2001 2002 2003 Year E x po rt v a lu e ( m il li on b a h t/y e a r) Domestic refrigerator Comercial refrigerator23
4. Pilot Project:
Eco-compressor
z
Collaborative project between government and industry
strategic partner
z
Signing an cooperative agreement between MTEC and
SUE (KPC) on August 27, 2003
24
Demonstration Project to Produce Prototype of
a more Environmental Friendly Compressor
Redesign parts
Cast iron
parts
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
26
Current Situation
¾
Eco-Design Part
o JODC-Expert dispatch: Mr.Akira Arai, visit 3 times
(7-11 June 04, 22-26 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
27
Mr.Akira Arai (3 Visits): Advice on
Compressor Design
28
29
Performance Test of Compressor
Type
z
Current model
z
New model I (connecting
rod + piston + crankcase
(bush) as sinter)
Cooling
capacity
(BTU/hr)
468.3
459.1
COP
(W/W)
1.503
1.549
Noise
(dB A)
36.46
36.10
30
z
Goal
z
to determine the net improvement of environmental
impact of a new prototype compressor
(comparison of a conventional & new prototype compressor)
z
Product:
z
Reciprocating compressor (model 110 W)
z
Functional unit
z
Refrigerated temperature at 5
o
C for 10 years with an ambient
temperature at 32
o
C
31
Simplified Process Tree for a Compressor’s Life-Cycle
main assembly
PE
Al ingot
injection
disposal
use in
refrigerator
cast iron
machining
steel sheet
stamping
forming
small parts
forming
painting/
packing
injection
moulding
electricity
washing
Cu tube
forming
shell
assembly
silicon steel
cutting
cutting
Cu
wire
stator
assembly
rotor
assembly
suction
assembly
32
Plastics
Aluminium
Copper
Steel
Paints
Hot Rolled Sheet
Cold Rolled Sheet
Silicon Steel
Cast Iron
Parts Supplier
Manufacturing
Plant
Production of Compressor
Compressor33
Emission to Water
pH
7.4
BOD
xxx kg
COD
xxx kg
SS
xxx kg
Grease & Oil xxx kg
Waste water xxx L
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
Emission to Air
CO
xxx kg
CO
2xxx kg
NO
Xxxx kg
SO
Xxxx kg
VOC
xxx kg
H3PO4 xxx kg
Mn
xxx kg
Ethylene Glycol xxx kg
Compressor Factory
Energy Uses
Electricity xxx kWh
LPG xxx
m
3Fuel Oil
xxx L
Solid Waste
Steel scrap xxx kg
Cast iron waste xxx kg
Inventory Data of the Compressor
34
Main Materials of Compressor
Steel 71.93% Others 0.24% Al 2.21% Paint 0.21% Plastic 0.63% Cast iron 14.25% PM part 0.29% Copper 10.24%
35 -0.1 -0.05 0 0.05 0.1 0.15 0.2
Materials Production Disposal
S ingl e s c or e ( P t) summer smog winter smog carcinogens heavy metals eutrophication acidification ozone layer greenhouse
36 0 0.01 0.02 0.03 0.04 0.05 0.06 0.07 0.08 Stator core Magnet wire
Rotor core Cast iron parts
Shell Al ingot Crank shaft Si ngl e s c or e ( P t) summer smog winter smog carcinogens heavy metals eutrophication acidification ozone layer greenhouse
37
Life Cycle Impact Assessment
based on Categories
A nalyzing 1 p assembly 'Main Process Compressor'; Method: EDIP/UMIP 96 / EDIP World/Dk / characterization % 0 10 20 30 40 50 60 70 80 90 100 Global w armi Ozone depletion A cidif ic ation Eutrop hicati Photoc hemi Ecotoxi city Ecotoxi city Ecotoxi city soil Human toxicit y Human toxicit y Human toxicit y Bulk w aste Hazard ous Radioa ctive Slags/a shes Resour ces Stator A ssy OP1 Cylinder A ssy Plate Support A ssy V alve Head A ssy Spring A ssy Disch pipe A ssy Suction Muf f ler A ssy Shell A A ssy(A lkaline) Shell B A ssy(A lkaline) Compressor A ssy Dry of Oven CS Welding Leak Test Pre Treatment ED Painting ED Oven N2 Charg(Fianl Line)
100 100 100 100 100 100 100 100 100 100 100 100 100
0
38
Conclusions
z
This Eco Compressor project is the first
formal LCA-EcoDesign combination
project in Thailand
z
It is still a learning RD&E process
between KPC+MTEC with a technical
support from Japan through GPP
z
The final result of this project is expected
to be in the 3
rd
quarter of 2006
39
