Michael Overcash

Methodology for systematic analysis and improvement of manufacturing unit process life cycle inventory (UPLCI) CO2PE! initiative (cooperative effort on process emissions in manufacturing). Part 2: case studies

PurposeThis report proposes a life-cycle analysis (LCA)-oriented methodology for systematic inventory analysis of the use phase of manufacturing unit processes providing unit process datasets to be used in life-cycle inventory (LCI) databases and libraries. The methodology has been developed in the framework of the CO2PE! collaborative research programme (CO2PE! 2011a) and comprises two approaches with different levels of detail, respectively referred to as the screening approach and the in-depth approach.MethodsThe screening approach relies on representative, publicly available data and engineering calculations for energy use, material loss, and identification of variables for improvement, while the in-depth approach is subdivided into four modules, including a time study, a power consumption study, a consumables study and an emissions study, in which all relevant process in- and outputs are measured and analysed in detail. The screening approach provides the first insight in the unit process and results in a set of approximate LCI data, which also serve to guide the more detailed and complete in-depth approach leading to more accurate LCI data as well as the identification of potential for energy and resource efficiency improvements of the manufacturing unit process. To ensure optimal reproducibility and applicability, documentation guidelines for data and metadata are included in both approaches. Guidance on definition of functional unit and reference flow as well as on determination of system boundaries specifies the generic goal and scope definition requirements according to ISO 14040 (2006) and ISO 14044 (2006).ResultsThe proposed methodology aims at ensuring solid foundations for the provision of high-quality LCI data for the use phase of manufacturing unit processes. Envisaged usage encompasses the provision of high-quality data for LCA studies of products using these unit process datasets for the manufacturing processes, as well as the in-depth analysis of individual manufacturing unit processes.ConclusionsIn addition, the accruing availability of data for a range of similar machines (same process, different suppliers and machine capacities) will allow the establishment of parametric emission and resource use estimation models for a more streamlined LCA of products including reliable manufacturing process data. Both approaches have already provided useful results in some initial case studies (Kellens et al. 2009; Duflou et al. (Int J Sustain Manufacturing 2:80–98, 2010); Santos et al. (J Clean Prod 19:356–364, 2011); UPLCI 2011; Kellens et al. 2011a) and the use will be illustrated by two case studies in Part 2 of this paper (Kellens et al. 2011b).

Recycling of fiber-reinforced composites and direct structural composite recycling concept

Fiber-reinforced polymer composites are engineered materials commonly used for many structural applications because of the high strength-to-weight and stiffness-to-weight ratios. Although the service life of these materials in various applications is usually between 15 and 20 years, these often keep the physical properties beyond this time. Recycling composites using chemical, mechanical, and thermal processing is reviewed in this article. In this review of carbon, aramide, and glass fiber composites, we provide, as of 2011, a complete view of each composite recycling technology, highlight the possible energy requirements, explain the product outputs of recycling, and discuss the quality (fiber strength) of recyclates and how each recyclate fiber could be used in the market for sustainable composite manufacturing. This article also includes the new concept of ‘direct structural composite recycling’ and the use of these products in the same or different applications as low-cost composite materials after small modifications.

Industrial Ecosystem Development at the Metropolitan Level

This article presents the result of a two‐year project funded by the U.S. Environmental Protection Agency to identify potential by‐products partnerships between industries in a six‐county metropolitan area in North Carolina, U.S.A. The project gathered data from 182 industries and institutions in the region regarding (1) by‐products that might be usable by other, nearby firms, and (2) the inputs they used that might be furnished from another facilitys by‐products. These data, which were also linked to geographic information system maps, were used to identify potential regional partnerships for the reuse of materials, water, and energy. Of the 182 participating facilities, probable or possible partnerships were found for 48% during the limited project period. This project demonstrated the value of a local facilitator and the value of specific techniques for identifying and promoting potential by‐products partnerships.

Life cycle and nano-products: end-of-life assessment

Understanding environmental impacts of nanomaterials necessitates analyzing the life cycle profile. The initial emphasis of nanomaterial life cycle studies has been on the environmental and health effects of nanoproducts during the production and usage stages. Analyzing the end-of-life (eol) stage of nanomaterials is also critical because significant impacts or benefits for the environment may arise at that particular stage. In this article, the Woodrow Wilson Center’s Project on Emerging Nanotechnologies (PEN) Consumer Products Inventory (CPI) model was used, which contains a relatively large and complete nanoproduct list (1,014) as of 2010. The consumer products have wide range of applications, such as clothing, sports goods, personal care products, medicine, as well as contributing to faster cars and planes, more powerful computers and satellites, better micro and nanochips, and long-lasting batteries. In order to understand the eol cycle concept, we allocated 1,014 nanoproducts into the nine end-of-life categories (e.g., recyclability, ingestion, absorption by skin/public sewer, public sewer, burning/landfill, landfill, air release, air release/public sewer, and other) based on probable final destinations of the nanoproducts. This article highlights the results of this preliminary assessment of end-of-life stage of nanoproducts. The largest potential eol fate was found to be recyclability, however little literature appears to have evolved around nanoproduct recycling. At lower frequency is dermal and ingestion human uptake and then landfill. Release to water and air are much lower potential eol fates for current nanoproducts. In addition, an analysis of nano-product categories with the largest number of products listed indicated that clothes, followed by dermal-related products and then sports equipment were the most represented in the PEN CPI (http://www.nanotechproject.org/inventories/consumer/browse/categories/2010).

The evolution of life cycle assessment in pharmaceutical and chemical applications – a perspective

This paper provides a broad strokes perspective on the evolution for the application of Life Cycle Assessment (LCA) within the pharmaceutical and chemical industries. This focus is mainly on the challenges faced to produce the needed inventory data and using the resulting LCA output in decision making, which are the backbone of any LCA estimation and practical application in industry. It also provides some of the insights the authors have derived over the last two decades of work in this area, and proposes a series of development needs within life cycle assessment as it becomes more integrated into decision-making in industry.

Unit Process Life Cycle Inventory for Product Manufacturing Operations

Rapid access to or generation of life cycle information is a potentially valuable tool for the design of products to meet the needs of sustainability improvement. A new approach is developed to use the manufacturing unit process, commonly outlined in manufacturing process taxonomy systems, as the basis for life cycle inventory. This will initially involve 50–70 unit processes from the taxonomy and will generate energy and mass profiles for each unit process life cycle (uplci). These uplci can be adjusted for each case to include the major variables affecting such operations as related to any specific product. The sum of the performance of a sequence of uplci thus provides the life cycle of the specific product from a defined set of plant process inputs.Copyright

Recycling of Aircraft: State of the Art in 2011

Recently, the end-of-service life for aging aircraft and related parts has become a key subject in recycling industries worldwide. Over the next 20 years, approximately 12,000 aircraft currently utilized for different purposes will be at the end of service. Thus, reclaiming retired aircraft by environmentally responsible methods while retaining some of the value becomes a significant need. Recycling aircraft components and using these in different applications will reduce the consumption of natural resources as well as landfill allocations. Compared to the production of virgin materials, recycling aircraft will also reduce air, water, and soil contaminations, as well as energy demand. In the present study, we have investigated the environmental benefits of recycling and reusing aircraft components in the same or similar applications as low-energy input materials. During the aircraft recycling, most of the aircraft components can be recycled and reused after reasonable modifications and investments.

Life Cycle Analysis of Grinding

Abrasive unit processes are key technologies to achieve high surface quality and dimensional tolerances with highly stable processes. Life Cycle Inventory provides a basis to evaluate the environmental aspects of unit processes. This paper will provide an integrated analysis of floor-to-floor cycle for product grinding as well as review the state-of-the-art for industrial grinding including cooling lubricants and specific energy. This work discusses existing approaches to evaluate grinding process sustainability and shows the applicability (and limits) of the UPLCI method. The goal is a workable, estimating approach that can be widely used in decisions for energy improvement and product life cycle.

Unit Process Life Cycle Inventory (UPLCI) – A Structured Framework to Complete Product Life Cycle Studies

Major life cycle studies of even moderately complex products have been limited to the life cycle of the product materials and possibly assembly of the final product. The intervening manufacturing transformation of materials/chemicals into products is thus a major segment not well represented by life cycle analysis tools. Yet these transformational manufacturing plants are a large and important industrial sector. In contrast the synthesis of chemicals or materials (often representing the supply chain) is well developed on the basis of connected unit processes (reactors, furnaces, heat exchangers, distillation, etc) to make chemical plant life cycle inventories. This paper addresses an international life cycle effort to develop a unit process approach for the manufacturing plant transformations of materials representing the majority of all product manufacturing plants. The UPLCI approach is thus an enabling technology in the life cycle field. This paper discusses the development of the UPLCI structure, recent successful efforts in verifying/improving UPLCI, the challenges of linking these in sequences to represent plants, and combining the manufacturing and the supply chain life cycle profiles. An important part of this effort is the CO2PE! Project which develops UPLCI data sets with a quality assurance system based on in-depth multi-plant field testing.

Climate zones and the influence on industrial nonprocess energy consumption

This paper begins with the recognition that climate zones influence nonprocess energy use in industrial buildings. Nonprocess energies are heating, cooling, lighting, and ventilation. Nonprocess energy data have been collected from the literature (about 68 buildings) across a wide range of climate zones. The hypothesis tested in this research is: if an industrial building has a characteristic nonprocess energy related to physical dimensions and desired comfort level, then using cooling degrees day (CDD) and heating degrees day (HDD) factors can normalize the measured nonprocess temperature control data for the climate zone differences. That is, do measured nonprocess energy intensities (W/m2), if corrected for climate zone differences, within each building category become more similar and hence reflecting the basic building temperature control energy use? The five U.S. climate zones and the location for each facility in this study were identified. To investigate how the location influences the amount of heating and cooling at each facility, a baseline analysis of five representative cities in each zone was done to obtain the 5-year average CDD and HDD. The reported values of heating and cooling for each facility were then adjusted using this baseline and the climate zones of that facility, so that each facility was then referenced to zone 3; that is, as if all manufacturing facilities were in the same zone 3. The mean, median, standard deviation, and total nonprocess energies for current and zone-adjusted nonprocess energy for each facility in this study were calculated. The mean values of current and adjusted heating and cooling remained close to each other and the standard deviation was not reduced by these adjustments. Thus, the hypothesis of using CDD/HDD to quantitatively account for and hence to adjust for different climate zones appears to not be valid. The absence of improvement (reducing the standard deviation) by normalizing heating and cooling energy using adjustment for climate factors using the concept of CDD/HDD implies that some other correction principles are needed for evaluating fundamental needs for industrial building heating and cooling. The inability to reduce the geographic (that is, climate zone) effects of industrial plant nonprocess energy intensities supports the de-emphasis of this tool in the ASHRAE Handbook.