Carla L. Simões

Integrating environmental and economic life cycle analysis in product development: a material selection case study

PurposeAchieving sustainability by rethinking products, services and strategies is an enormous challenge currently laid upon the economic sector, in which materials selection plays a critical role. In this context, the present work describes an environmental and economic life cycle analysis of a structural product, comparing two possible material alternatives. The product chosen is a storage tank, presently manufactured in stainless steel (SST) or in a glass fibre reinforced polymer composite (CST). The overall goal of the study is to identify environmental and economic strong and weak points related to the life cycle of the two material alternatives. The consequential win–win or trade-off situations will be identified via a life cycle assessment/life cycle costing (LCA/LCC) integrated model.MethodsThe LCA/LCC integrated model used consists in applying the LCA methodology to the product system, incorporating, in parallel, its results into the LCC study, namely those of the life cycle inventory and the life cycle impact assessment.Results and discussionIn both the SST and CST systems, the most significant life cycle phase is the raw materials production, in which the most significant environmental burdens correspond to the Fossil fuels and Respiratory inorganics categories. The LCA/LCC integrated analysis shows that the CST has globally a preferable environmental and economic profile, as its impacts are lower than those of the SST in all life cycle stages. Both the internal and external costs are lower, the former resulting mainly from the composite material being significantly less expensive than stainless steel. This therefore represents a full win–win situation. As a consequence, the study clearly indicates that using a thermoset composite material to manufacture storage tanks is environmentally and economically desirable. However, it was also evident that the environmental performance of the CST could be improved by altering its end-of-life stage.ConclusionsThe results of the present work provide enlightening insights into the synergies between the environmental and the economic performance of a structural product made with alternative materials. Furthermore, they provide conclusive evidence to support the integration of environmental and economic life cycle analysis in the product development processes of a manufacturing company or, in some cases, even in its procurement practices.

Environmental and economic assessment of a road safety product made with virgin and recycled HDPE: a comparative study.

The development of value-added products made from post-consumer plastic recyclates has become an important goal in the quest for a sustainable society. To attain such goal, tools with higher accuracy and wider scope are increasingly necessary. The present work describes the application of a Life Cycle Assessment (LCA)/Life Cycle Costing (LCC) integrated model, with inclusion of externalities (environmental and social costs), to Anti-Glare Lamellae (AGL) made with High Density Polyethylene (HDPE). It compares an AGL currently manufactured from virgin HDPE (current AGL) with an alternative one made with recycled HDPE (optional AGL). The results obtained show that neither the current nor the optional AGL depict the best environmental performance in all impact categories. Nevertheless, there is a clear overall environmental and economic advantage in replacing virgin HDPE with recycled HDPE. The present work also makes evident that the LCA/LCC integrated model allows the identification of economic and environmental win-win and trade-off situations related to the full life cycle of products. As such, its results can be used as valuable guidelines in product development.

Influence of the Impact Assessment Method on the Conclusions of a LCA Study. Application to the Case of a Part Made With Virgin and Recycled HDPE

Recent legislation has stressed the need to decide the best end-of-life (EoL) option for post-consumer products considering their full life-cycle and the corresponding overall environmental impacts. The life cycle assessment (LCA) technique has become a common tool to evaluate those impacts. The present study aimed to contribute to the better understanding of the application of this technique, by evaluating the influence of the selection of the life cycle impact assessment (LCIA) method in its results and conclusions. A specific case study was chosen, using previous information related to an anti-glare lamellae (AGL) for highway use, made with virgin and recycled high-density polyethylene (HDPE). Five distinct LCIA methods were used: Eco-indicator 99, CML 2 (2000), EPS 2000, Eco-indicator 95 and EDIP 97. Consistent results between these methods were obtained for the Climate change, Ozone layer depletion, Acidification and Eutrophication environmental indicators. Conversely, the Summer smog indicator showed large discrepancies between impact assessment methods. The work sheds light on the advantages inherent in using various LCIA methods when doing the LCA study of a specific product, thus evidencing complementary analysis perspectives.

Modelling the economic and environmental performance of engineering products: a materials selection case study

PurposeLife cycle assessment (LCA) studies allow understanding all relevant processes and environmental impacts involved in the life cycle of products. However, in order to fully assess their sustainability, these studies should be complemented by economic (LCC) and societal analyses. In this context, the present work aims at assessing all costs (internal and external) and the environmental performance associated to the full life cycle of specific engineering products. These products are lighting columns for roadway illumination made with three different materials: a glass fibre reinforced polymer composite, steel and aluminium.MethodsThe LCA/LCC integrated methodology used was based in a “cradle-to-grave” assessment which considers the raw materials production, manufacture, on-site installation, use and maintenance, dismantlement and end-of-life (EoL) of the lighting columns. The fossil fuels environmental impact category was selected as the key environmental impact indicator to perform the integrated environmental and cost analysis.ResultsThe potential total costs obtained for the full life cycle of the lighting columns demonstrated that the one made in steel performs globally worse than those made in composite or aluminium. Although the three systems present very similar internal costs, the steel column has higher external costs in the use phase that contribute for its higher total cost. This column has very high costs associated to safety features, since it constitutes a significant risk to the life of individuals. The raw material and column production stages are the main contributors for the total internal life cycle costs. The EoL treatment is a revenue source in all systems because it generates energy (in the case of the composite incineration) or materials (in the case of metal recycling). The composite and aluminium lighting columns present similar “cradle-to-grave” life cycle total cost. However, until the dismantlement phase, the aluminium column presents the highest environmental impact, whereas in the EoL treatment phase this scenario is reversed. The “cradle-to-grave” life cycle potential total cost and the environmental impact (fossil fuels) indicator of the steel lighting column are higher than those of the other columns.ConclusionsEven though the uncertainties in the LCC are larger if external costs are included, their consideration when modelling the economic performance of engineering products increases the probability of developing a more sustainable solution from a societal perspective.

Life cycle assessment of a road safety product made with virgin and recycled HDPE.

The present study aims at evaluating the potential environmental impact of using recycled high-density polyethylene (HDPE) in the production of an anti-glare lamella (AGL), a road safety device currently manufactured from virgin (not recycled) polymer. The impact was evaluated using the life cycle assessment (LCA) technique and comparing two alternative systems: current AGL, manufactured from virgin HDPE, and optional AGL, made with recycled HDPE obtained from post-consumer packages. The AGL manufacturing phase was found to be responsible for most of the impacts in both systems, with the production of the raw material being the largest contributor for that phase. The present study makes a contribution to the problem of developing value-added products made from post-consumer polymeric recyclates.

Environmental and economic analysis of end of life management options for an HDPE product using a life cycle thinking approach

Manufacturers have been increasingly considering the implication of materials used in commercial products and the management of such products at the end of their useful lives (as waste or as post-consumer secondary materials). The present work describes the application of the life cycle thinking approach to a plastic product, specifically an anti-glare lamellae (used for road safety applications) made with high-density polyethylene (HDPE). This study shows that optimal environmental and economic outcomes associated with this product can be realized by recovering the material at the end of its useful life (end of life, EoL) and by using the recycled HDPE as a raw material in the production of new similar products. The study confirmed the applicability of the life cycle thinking approach by industry in sustainable products development, supporting the development of robust environmental and economic guidelines.