Life Cycle Analysis with Application to Consumer Products and Pharmaceuticals

1. Life Cycle Analysis with Application to Consumer Products and Pharmaceuticals A three session introduction to performing and interpreting a life cycle analysis David Hitchcock, Mariano J. Savelski, C. Stewart Slater Rowan University, Department of Chemical Engineering, Glassboro, NJ 08028 September 2011

2. Three Sessions Overview • Session 1 • Overview of Life Cycle Analysis • Session 2 • How to use environmental assessment software, SimaPro® • Session 3 • Modeling processes in SimaPro®

3. Life Cycle Analysis General Concepts Session 1

4. Overview • Defining LCI and LCA • The steps of performing a life cycle analysis • Defining the goal and scope of your project • What do you hope to achieve and what the boundaries of the project are • The basics of process modeling • An introduction to environmental impact assessment

5. LCI – Life Cycle LCA- Life Cycle Inventory Analysis • Summary of all the emissions associated with the product or energy used • Based on 1kg of the product or 1 MJ of energy • Summary of all the emissions associated with the entire process • Raw materials manufacturing • Energy used • Waste Treatment • Multiply the inventory by the quantity used to generate the LCA i= individual contributors Q= quantity of i

6. Performing an LCA Available for purchase from http://www.iso.org/ The International Standards Organization website There are four main phases in an LCA. • Defining the goal and scope • Inventory assessment • The methods for phases 1 and 2 have been standardized as can be found in ISO 14040 – ISO 14043. Standards are followed because it is the most widely accepted method for completing your project. Following the standards gives your results more credibility.

7. Performing an LCA • Impact assessment • A quantification of how the product or process affects the environment e.g. CO2 emissions, heavy metals, and land occupation • Interpretation of Results Phases 3 and 4 have not been standardized. Make sure to use the same method for these phases throughout the entire project to maintain validity and credibility.

8. The Goal • Consider the following: • Why is this study being performed? • Do you want to know the overall environmental impact or just one component of it such as CO2 emissions? • What is its application? • The results may be used for economic reasons such as a CO2 tax • The results may be used as a basis for changing the process or raw materials used to decrease the environmental impact • Who will see the results? • If the results are for the public, keep details such as specific chemicals and processes hidden while still providing accurate results

9. Defining the Scope • The scope is defined by: • The boundaries that you set for the process • Where your assessment starts and ends • The basis of comparison e.g. amount produced, amount required for a specific purpose, or a specified amount such as 1kg of product • Will you ignore the production of useful byproducts or consider it? • What environmental impacts are considered and how they are calculated • The data that will be required and quality of it • What data do you need that is missing and what assumptions can you reasonably make? • How accurate do you want the missing data to be?

10. Life Cycle Assessment Material extraction Material processing Manufacturing Use Waste management Recycle Re-manufacture Re-use Cradle Where all raw materials begin Gate Where everything enters the plant Gate Where everything exits the plant Grave The end of the product’s life The life cycle of a product includes many inputs. The raw materials and the energy required for every process contribute to the emissions and cost associated with a product An LCA can be performed over any boundary

11. Things to Consider for the System Boundary Where the analysis begins and ends Inputs and outputs in the manufacturing/process sequence Production and use of fuels, electricity, and heat Manufacture, maintenance and decommissioning of process equipment Requirements to run the plant Process waste disposal Manufacture of useful byproducts Distribution/transportation of product Post production utilization Recovery and recycling of used products

12. The Basis of an LCA • To examine the environmental impact associated with a product you need to choose a basis • 1 kg of product is a typical basis for an LCA, but many other bases can be used • This is necessary when comparing different products or processes • Comparing products that serve the same purpose e.g. alkaline and rechargeable batteries • Comparing different processes for making the same product e.g. making fudge by hand or in a factory

13. The Basis for Product Comparison • When comparing different products it is useful to define the basis as the product’s utility • For example compare rechargeable NiMH and alkaline batteries • Use the lifetime of 1 pack of rechargeable batteries as the basis • 500 packs of alkaline batteries have the same lifetime as 1 pack of rechargeable batteries

14. The Basis for Product Comparison contd. • This is the comparison using 750mAh, 1.2V NiMH batteries and a comparable AAA alkaline battery • It takes 0.0045 kWh to recharge four of these batteries, or 1 pack • NiMH batteries cost $15.99 while Alkaline batteries cost $5.49 • The average U.S. electricity cost for 2011 was used (0.127$/kWh) • It was assumed that the two types of batteries were produced using very similar processes so the raw materials and waste are the same • This is only a comparison of the production and energy consumption of batteries • For this basis of comparison, the rechargeable batteries have a lower environmental impact and overall cost to the consumer.

15. The Basis for Process Comparison When comparing processes it is useful to define the basis as the process output (product unit) For example compare the environmental impact associated with the production of 1 kg of fudge by two different production routes

16. Useful Byproducts • You can either ignore these or consider them in you analysis • If you choose to consider them: • Know how much is produced • Calculate or research the environmental impact associated with the production of the byproducts • This is based on a process where your byproducts are the desired product • Credit this impact to your process • Account for by subtracting from the final LCA

17. Environmental Impacts Considered Provided for you • The project sponsor or your client often provides the environmental impacts to examine Not provided for you • You have to chose the environmental impact(s) • Air emissions • Water emissions • Soil emissions • Each category has individual emissions such as CO2, NOx, VOCs, and heavy metals

18. The Basics of an LCI • The LCI data may be provided to you by your professor or sponsor • If this is not the case you can generate the LCI (shown in sessions 2&3) or you can research for the required data • http://www.cpm.chalmers.se/CPMdatabase/Start.asp • This site provides LCIs of many products and processes • Specific literature such as The International Journal of Life Cycle Assessment

19. LCI Tables Note: the table can be organized in any way, such as individual pollutants or types of energy used Below is one type of table used to summarize the LCIs of compounds and manufacturing processes

20. Jar of Peanut Butter Process Map Peanuts Roasting/Grinding Distribution Center Sugar Waste Mixing Oil Individual Packaging Retailer Jar Production Glass Polypropylene Lid Production Paper Carton Recycling Printer Ink Carton Packaging Box printing/ forming User Storage and consumption Cardboard Film Shrink Wrapping

21. A Closer Look Emissions Emissions Emissions Product Raw Materials Manufacture Manufacturing Process Raw Materials Waste Waste Management Raw Materials Energy Energy Energy Raw Materials Each box in the manufacturing section of the process map is simplified Below is a general diagram of a manufacturing process

22. Lets Make Chocolate Fudge! http://www.fudge-recipe.com/old-fashioned-fudge-recipe.html http://www.amfudge.co.za/how_is_fudge_made_.html • What are the required ingredients? • Milk, chocolate, sugar, corn syrup, salt, butter, additional flavors e.g. nuts, vanilla, mint • How is the fudge made? • Melt chocolate with milk • Mix the sugar, corn syrup, and salt • Boil the mixture • Mix in butter and flavoring • Allow to cool • Cream the fudge by aerating it • Allow to cool and form into desired shape • What materials are used for packaging? • Paper, cardboard, and ink • What about distribution and sales? • Distribution Center-> Retailer -> Consumer • Sold directly to the consumer • Waste and recycling of packaging

23. Fudge Process Map Milk Distribution Center Mixing/Melting Chocolate Waste Mixing/Boiling Sugar Retailer Cooling Corn Syrup Creaming Salt Cooling/Shaping User Storage and consumption Butter Flavors Packaging Carton Recycling Paper Box printing/forming Cardboard Ink

24. Breakfast LCA Amounts needed for one bowl of oatmeal • Calculate the LCA of an individual serving of breakfast • Given: • LCIs for each component • Milk, oat flakes, water, and boiling water (for oatmeal)

25. Breakfast LCI’s • Energy and waste are already included in these LCIs so they do not need to be added to the LCA • The milk LCI can be traced back to the beginning of a farm

26. Calculating the LCA Raw Materials Process Energy Disposal R = Amount of Raw Material used in manufacture of the chosen basis of product E = Energy used to produce the chosen basis of product W = Waste emissions associated with producing the chosen basis of product r = number of raw materials e = different type of energy used w = number of waste streams that are sent to waste treatment

27. Breakfast LCA

28. Breakfast LCA • 0.148 kg total emissions • Total Emissions contributed to breakfast by each ingredient

29. Questions?

30. Using SimaPro® 7.2 multiuser Session 2

31. Overview • What is SimaPro® • How to use the program • Generating an LCI • Modeling your own process • Some specific components of SimaPro® are explained along the way

32. SimaPro® • SimaPro® is a detailed environmental analysis tool • Used for a product or process • Products and processes are called processes in this program • Quantification of the raw material, energy use, and emissions to the air, water, and soil • Characterization of environmental impacts • The databases contain many common products and processes, but not everything • Products and processes not already in the databases need to be evaluated differently as discussed later • A free trial of the Software is available at http://www.pre.nl/content/download-simapro-7

33. What SimaPro® Contains • Databases • Inventory of the data in SimaPro® • Substances, “processes”, units, conversion factors, environmental impact categories, projects, libraries • Projects (what you will be working on) • The data used in a specific project • Library • Data available for use in all projects • General data • Data such as substances and units

34. Starting SimaPro® For use in Rowan Hall Start->All Programs->SimaPro 7.2 Multiuser->SimaPro 7.2 Multiuser

35. This is the opening screen of SimaPro • Click to proceed

36. You will then be presented with this screen where you can select the server that you will use • For the first time, there will be no servers • You will need to add the server(s) you wish to use.

37. Click • In the new window that appears click • In this window enter the server name • Our server is “specter” • Click

38. Click • Make sure that “Professional” is highlighted as shown to the left • This is the most current version • Click

39. Wait for the database to finish loading • Select a user • Select Expert, user ##, or Manager whenever possible • Expert can view and edit all expert, practioner, and visitor projects • Manager and user## can view and edit all projects in the database • Practioner can only open projects on that level and default tutorials, but can create projects • Visitor can only open default tutorials and cannot create projects • The Password is the username • Ex. The password for Expert is “expert”

40. The Project selection window will appear • From here you can select an existing project or create your own • To open and existing project click To create a new project click

41. When creating a new project this screen will display • Enter the name of your project • Use a concise and descriptive name like “Slater LCA Tutorial” • Click

42. The top bar • This is a screen similar to what you should see after following the previous steps • This is the main screen of SimaPro® (the LCA explorer screen) where you are able to do everything SimaPro® is capable of • Note that this is the processes tab of the LCA explorer The far left bar

43. Project Management • Create a new project • Open an existing project • Close the current project • Save the current item being edited • Print the current item • Cut the selection • Copy the selection • Paste the selection • Find an item within SimaPro®

44. Editing tools • Inserts a new line for input • Deletes the currently selected input line • Used when creating a process in SimaPro® • Expression tools • In SimaPro® the user can input mathematical expressions instead of numbers • Displays the expressions entered and their results • Updates all expressions (This is automatically done by default)

45. Analysis Shortcut tools • The analysis options are discussed in detail later • Performs a network analysis • Performs a impact assessment analysis • Compares the selected processes using an impact analysis • SimaPro® tools • Shows the LCA explorer window • This button allows you to view the data from all of the projects • This button is only available for the “manager” and “user##” users because they can view all processes • It does not allow you to edit processes from other projects, only view and analyze them

46. The far left bar provides links to use for navigating the program • Wizards • This provides some pre-loaded tutorials and an LCA-wizard that you can use when creating a new LCA model • Goal and Scope • “Description” allows you to define and view a description of the current project • “Libraries” displays the list of libraries and allows you to select which libraries are used in the project

47. Inventory • “Processes” is the window that was shown earlier where you can navigate through the processes available in your project • “Product stages” allows you to define what processes are included in the different stages of your process (assembly, life cycle, disposal, disassembly, and reuse) • “Wastetypes” displays a list of the different types of waste management available in SimaPro® • These are labels that tell SimaPro® how to treat the waste produced by a process • “Parameters” allows the user to define variables, both independent and dependant, for use in the LCA model • These can be used in expressions for process inputs/outputs

48. Impact assessment • “Methods” displays a list of the available impact assessment methods • You can create your own methods tailored to your requirements • “Calculation setups” displays a list of the available calculation methods • You can create a setup to display the results that you choose in a specific format so that all repeat calculations are presented the same way

49. Interpretation • “Interpretation” allows the user to input an interpretation of the data • “DocumentLinks” provides links to the documentation that corresponds to the selected libraries

50. General Data • “Literature references” displays a list of the literature cited by the libraries in use • “Substances” displays a list of the available substances • “Units” displays a list of the units used in SimaPro® • “Quantities” displays the units sorted by what physical quantities they represent • “Images” displays all of the images used by the selected libraries including images of processes