Application of LCA & EcoDesign in Eco-Products Development:

Case Study for Eco-compressorby

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 Technology2 Kulthorn Premier Co., Ltd.

International Workshop on“Capacity Building on Life Cycle Assessment in APEC Economies”Bangkok, Thailand, December 15 - 16, 2005

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Contents 1. Environment Legislations Overview2. Introduction to LCA 3. Introduction to EcoDesign4. Pilot Project: Eco-compressor

3

Source: EGG 2004+ Materials

1.Environment Legislation Overview; EU Legislation

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 lawsfor individual

fields

Japan Legislation (all laws below are already enforced)

Source: Eco-management Institute (Japan)

5

Other Countries

China: WEEE/RoHS (Aug 2006)USA: California; EE Recycle Law & RoHS

(enforce together with EU)Hawaii; Ban PBDE (Jan 2006)

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Solution

Need to go “Green”GREEN COMPETITIVENESS

Tools:CT + LCA + EcoDesign

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Product Life Cycle “From Cradle to Grave”

Impacts on • Human health• Ecosystems• Resources

2. Introduction to LCA

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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

Source: UNEP (1999)

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Road Map - ISO 14000Management

Systems

ISO 14004 (EMS)

general guidelineson principles, systems

& supportingtechniques

ISO 14001 (EMS)

specification withguidance for use

Evaluation &Auditing Tools

EnvironmentalPerformance

Evaluation (EPE)

ISO 14031 guidelines

EnvironmentalAuditing (EA)

14010 general principles

14011-1 audit procedures

14012 qualification criteriafor environmentalauditors

Product-OrientedSupport Tools

Life Cycle Assessment (LCA)14041 general principles &

practices14042 life cycle inventory analysis14043 life cycle impact assessment14044 life cycle improvement

assessment

Environmental Labelling (EL)14020 basic principles for all

environmental labelling14021 terms & definitions14022 symbols14023 testing & verification14024 guiding principles, practices

& criteria for certificationprograms

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ISO 14040 Life Cycle Assessment, Principles and Framework

Life cycle assessment framework

Goal and scopedefinition

Inventoryanalysis

Impactassessment

Inter-pretation

Direct applications:- Product developmentand improvement

- Strategic planning- Public policy making- Marketing- Other

Source: ISO 14040 (ISO, 1997)

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Foreground Data

Materials

Electricity Fuels

Manufacturing Use Disposal

Mining

Background Data

Life Cycle Inventory Analysis (LCI)

Ref: Dr.INABA, AIST

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Utilization of LCA Voluntary

ImprovementMarketing

Reflection to Social/Economic

SystemsConsumption

Activity

Design for Environment (DfE)

Appealing (Public Relations)

Environmental ReportsEnvironmental Labeling

Environmental EducationLifestyle Review

GreenProcurement

Environmental Administration(Support for recycling, etc)

Information DisclosureEnvironmental Management System

Recycling DesignProcess Improvement

LCA

Ref: Ishizaka, Nagano prefecture

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3. Introduction to EcoDesignProduct Design is a critical determinant of a manufacturer’s competitivenessNational Research Council, USA: estimates that 70% or more of the costs of product development,manufacture and use are determined during theinitial design stagesBad design leads to inefficient use of resourcesand excessive wasteTrade Barriers using environmental aspects(packaging / hazardous substances / product recyclability etc.)

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What is EcoDesign?EcoDesign is a design approach that leads to a profitable balance between ecological and economical requirements when developing products.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.

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What can be achieved with EcoDesign?

Considerable reduction in environmental load (e.g., 30-50% or higher) – often feasible in short termSaving of materials and energyReduction in wasteInnovative product designConsiderable 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

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UNEP Eco-Strategies Wheel

1Selection 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)

2Reduction of material•Reduction in weight •Reduction in (transport) volume

3Optimization of production techniques•Alternative production techniques •Fewer production processes •Low/clean energy consumption •Low generation of waste •Few/clean production consumables

4Efficient distribution system••Less/clean packaging •Efficient transport mode •Efficient logistics

5Reduction of the environmentalimpact in the user stage•

•Low energy consumption •Clean energy source •Few consumables needed during use •Clean consumables during use •No energy/auxiliary material use

6Optimization of initial life-time••Reliability and durability •Easy maintenance and repair •Modular product structure •Classic design •User taking care of product

7Optimization of end-of-life system•Reuse of product •Remanufacturing/refurbishing •Recycling of materials •Clean incineration

+- +-

Existing product

Priorities for the new product

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EcoDesign Process Flow

Detailed Design

Approval

Quantitative (Final) Design Review

Target Product / Parts

Analysis and Evaluation of the Present Design

Conceptual Design

Phase IPlanning

Phase IIAnalysis &Generation

Phase IIIDesign &

Development

Phase IVVerifying

& Approval

LCAEco-Indicator

QFDE

DFE Checklist

EcoDesign Tools EcoDesign Phases

Qualitative Design Review

Product Concept Making

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17%5%

7%

19%

2%4% 46%

Air conditionerRefrigeratorRice cookerFansWashing MachineWater boilerOther

Source: Conclusion Report (2000) of “Consulting Assignment-Load Research Program”, EGAT

Electricity consumption in residential sector

Source: EGAT Public Company Ltd. (2000)

Energy Consumption of Various Home Appliances

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Environmental impact of compressor usage

Electricity ConsumptionElectricity Consumption of Refrigerator is 20% of residential sectorAcidification & Green House Effect from Energy Consumption

Solid wasteSteel scrap, Slag

CFC Substance EmissionOzone depletion

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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

Cap

acity

(uni

t/ ye

ar)

Rotary Com.Scroll Com.Reciprocating Com.

Production Capacity of each type compressor in Thailand

Source: Siam Compressor Industry Co., Ltd. (2003)

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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

Pro

duct

ion

(Uni

ts/y

ear)

Compressor

Refrigerator

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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

Expo

rt v

alue

(mill

ion

baht

/yea

r)

Domestic refrigeratorComercial refrigerator

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4. Pilot Project: Eco-compressor

Collaborative project between government and industry strategic partnerSigning an cooperative agreement between MTEC and SUE (KPC) on August 27, 2003As a pilot project of the NETH program of GMTAP

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Demonstration Project to Produce Prototype of a more Environmental Friendly Compressor

Redesign partsCast iron parts

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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 company & Japanese counterparts (e.g. JETRO, JODC)

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Current SituationEco-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 partso 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 testo Mechanical testing of the connecting rod

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Mr.Akira Arai (3 Visits): Advice on Compressor Design

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Mold Making & Eco-Parts

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Performance Test of Compressor

Type

Current modelNew model I (connecting rod + piston + crankcase (bush) as sinter)

Cooling capacity (BTU/hr)

468.3459.1

COP (W/W)

1.5031.549

Noise (dB A)

36.4636.10

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Goalto determine the net improvement of environmental impact of a new prototype compressor (comparison of a conventional & new prototype compressor)

Product:Reciprocating compressor (model 110 W)

Functional unitRefrigerated temperature at 5o C for 10 years with an ambient temperature at 32o C

LCA Part

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Simplified Process Tree for a Compressor’s Life-Cycle

main assembly

PE Al ingot

injection

disposal

use in refrigerator

cast iron

machining

steel sheet

stampingforming

small parts

forming

painting/packing

injectionmoulding

electricity

washing

Cu tube

forming

shell assembly

silicon steel

cutting cutting

Cu wire

stator assembly

rotor assembly

suction assembly

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Plastics

Aluminium

Copper

Steel

Paints

Hot Rolled SheetCold Rolled Sheet

Silicon SteelCast Iron

Parts Supplier

ManufacturingPlant

Production of Compressor

Compressor

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Emission to Water

pH 7.4BOD xxx kgCOD xxx kgSS xxx kgGrease & Oil xxx kgWaste water xxx L

Materials/Resources

Steel xxx kgCast Iron xxx kgCopper xxx kgAl xxx kgPlastic xxx kgPaint xxx kgBA oil xxx LGear Oil xxx LNUTO Oil xxx LTelluse Oil xxx LCutta Oil xxx LMacron Oil xxx LLubricant xxx kgTrichloroethylene xxx LNano water xxx LWater xxx L

Emission to Air

CO xxx kgCO2 xxx kgNOX xxx kgSOX xxx kgVOC xxx kgH3PO4 xxx kgMn xxx kgEthylene Glycol xxx kg

Compressor Factory

Energy Uses

Electricity xxx kWhLPG xxx m3

Fuel Oil xxx L

Solid Waste

Steel scrap xxx kgCast iron waste xxx kg

Inventory Data of the Compressor

Compressor

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Main Materials of Compressor

Steel71.93%

Others0.24%

Al2.21%

Paint0.21%

Plastic0.63%

Cast iron14.25%

PM part0.29%

Copper10.24%

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-0.1

-0.05

0

0.05

0.1

0.15

0.2

Materials Production Disposal

Sing

le s

core

(Pt)

summer smogwinter smogcarcinogensheavy metalseutrophicationacidificationozone layergreenhouse

Life Cycle Impact Assessment of Compressor

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0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

Statorcore

Magnetwire

Rotor core Cast ironparts

Shell Al ingot Crankshaft

Sing

le s

core

(Pt)

summer smogwinter smogcarcinogensheavy metalseutrophicationacidificationozone layergreenhouse

Life Cycle Impact Assessment: main component

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Life Cycle Impact Assessment based on Categories

Analyzing 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

Ozonedepletion

Acidif ication

Eutrophicati

Photochemi

Ecotoxicity

Ecotoxicity

Ecotoxicity soil

Humantoxicit y

Humantoxicit y

Humantoxicit y

Bulkw aste

Hazardous

Radioactive

Slags/ashes

Resources

Stator Assy OP1 Cylinder Assy Plate Support Assy Valve Head Assy Spring AssyDisch pipe Assy Suction Muf f ler Assy Shell A Assy(Alkaline) Shell B Assy(Alkaline) Compressor Assy Dry of OvenCS 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

100 100

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ConclusionsThis Eco Compressor project is the first formal LCA-EcoDesign combination project in ThailandIt is still a learning RD&E process between KPC+MTEC with a technical support from Japan through GPPThe final result of this project is expected to be in the 3rd quarter of 2006

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ACKNOWLEDGEMENT

The technical support from Japanese Government through Green Partnership Plan (GPP) is acknowledged

Dr. Thumrongrut MungcharoenCleaner Technology Advancement Program (CTAP) National Metal and Materials Technology Center (MTEC)National Science and Technology Development Agency

Tel: (662) 644-8150-9 ext. 434 Fax: (662) 644-8041E-mail: thumrongrut@mtec.or.thwww.mtec.or.th/th/research/ctap