Life Cycle Assessment of Process Gas Boiler System Larsen & Toubro · © 2013 Larsen & Toubro...

© 2013 Larsen & Toubro Limited : All rights reserved

Life Cycle

Assessment of

Process Gas

Boiler System

Larsen & Toubro

8th November, 2013


Larsen & Toubro

Larsen & Toubro is a USD 14 Billion technology, engineering,

construction, manufacturing and financial services conglomerate with

global operations

© 2013 Larsen & Toubro Limited : All rights reserved 3

Powai Campus – Founded in 1958

Plate Cutting

Heavy Engineering - Powai

Machining

Welding Fabrication

© 2013 Larsen & Toubro Limited : All rights reserved 4

Plant Profile – Heavy Engineering

Design & Engineering

• System design, thermal / mechanical design, material and welding engineering

Technology Centre

•Process design, radar and transmitters, ship stabilizer, launcher designs and analysis

Manufacturing

•Heavy fabrication and machining test, site service

•200 mm thickness acetylene and plasma cutting

•1000 ton hydraulic press

•25000 ton rolling machine (hot & cold bending)

Welding

• SAW, TIG, MIG, SMAW, ESSC, FCAW processes, automatic and robotic welding

Machining

•CNC Horizontal and Vertical Boring, Turning, Drilling, Deep Hole Drilling

Fabrication

•Max Equipment Size: Weight – 400 Ton, Length - 47m, Diameter – 6m

•Destructive & Non Destructive Testing

Commissioning & Site Support


L&T – Product Responsibility


Background of LCA Study

Sr.

No. Parameters

Weightages

(Points)

1 Energy Efficiency 150

2 Water Conservation 100

3 Renewable Energy 100

4 GHG Emission Reduction 100

5 Material Conservation, Recycling & Recyclables 100

6 Waste Management 100

7 Green Supply Chain 100

8 Product Stewardship 75

9 Life Cycle Assessment 75

10 Others (Ventilation, Site Selection & Innovation) 100

“To promote and champion conservation of natural resources in Indian industry without compromising on high and accelerated growth"


Objective of LCA Study

• The main objective of the study is to evaluate the

“cradle-to-gate lifecycle” i.e. from raw material

acquisition, material production, transport,

assembly and fabrication data for Process Gas

Boiler system in order to calculate life cycle

inventories (“Life Cycle Inventory” or ”LCI”).

• To fulfil the requirements of GreenCo Rating

system


Life Cycle Assessment – L&T

“Compilation and evaluation of the inputs, outputs and the

potential environmental impacts of a product system

throughout its life cycle” – ISO 14040/44

Target

• To conduct the LCA of process gas boiler assembly (1 No. – 36 TPH

capacity).

• This product has been chosen as the Company has developed an expertise in

the manufacturing of the same over several years and it represents a

significant portion (> 25 %) of the Company’s order book (Powai – West) for

FY 2012-13.

• The Company expects to receive similar orders in future.


LCA study framework

Scope • To evaluate various

environmental impacts of all activities associated with fabrication of a process gas boiler assembly

System Boundary • The LCA of the process

gas boiler assembly covers the cradle to gate approach, consisting of raw materials transport, manufacturing, assembling, energy and auxiliary materials consumption till dispatch

Functional Unit • One Process Gas -

Waste Heat Recovery Boiler assembly having three subassemblies as steam drum, rise and down comer pipe and process gas boiler and capacity of 36TPH of steam generation.


LCA study - Flow chart

Goal and Scope

Definition

Data Collection and Data Quality Check

LCA System Modelling

(using GaBi Software)

LCI and LCIA calculations

and comparison if

any

Final Report

• Standards followed - ISO 14040/44 • Software used for modeling - GaBi 6 developed by PE International AG.


Natural

Resources

Air

Emissions

Water

Effluents

Solid

Waste

Life Cycle stages

Raw material acquisition

Material

processing

Production

Use and

maintenance

End-of-life

Cradle to gate boundary


System Boundaries

• The Life Cycle Analysis of one process gas boiler covers the cradle to

gate approach, consisting of raw materials transport, manufacturing,

fabrication, assembly, energy and auxiliary material consumption.

Life Cycle

stages

Life Cycle

sub-stages Definitions

Materials &

energy

production

Primary raw materials Raw material receipt

Sub components

Formation

Energy, fuel and raw materials used in the process of

formation of the primary sub components production

Upstream

Transport

Transport of the raw materials for primary production of the

assembly

Assembly Diesel, electricity and lubricating oil consumption during in-

house assembly of the boiler production and testing

In-house

locomotive In-house transport of various materials


Process Gas boiler breakup

Process gas boiler assembly

Riser & Down comer piping

Steam Drum General Assembly


1

3

4

LH-RH Dishend fabrication

2

7

9

8

10

5

6

Process Gas Boiler System

Shell fabrication

Tube sheet fabrication

Nozzle fabrication

External fabrication

Internal fabrication

Post Weld Heat Treatment

Hydro testing

Refractory

Dispatch


Data was collected from various functions on bill of materials, fuel, energy,

transportation which further were imported to the GaBi software for analysis.

Consolidated primary data for various machining and fabrication processes

are considered wherever part specific data was not available

The environmental profiles of various materials used in the fabrication of boiler

are sourced from GaBi 6 Professional 2012 databases wherein close

substitutes for materials are considered wherever the dataset was not available

Upstream transportation data has been considered in the assessment.

Data Collection & Assumptions


LCA – Environmental Impact

S.N Parameters

Process gas

Boiler

Assembly

(1)

Riser &

Down

comer

piping

(2)

Steam Drum

General

Assembly

(3)

Waste-Heat Recovery

Boiler Assembly

(1+2+3)

1 Acidification Potential (AP)

[kgSO2- Equiv.] 447.93 386.37 316.5 1,150.77

2 Global Warming Potential (GWP100 years) [kgCO2-

Equiv.] 1,02,115.36 74,507.01 91,644.3 2,68,266.64

3

Ozone Layer Depletion

Potential (ODP, steady state)

[kg R11-Equiv.]

0.00 0.00 0.00 0.00

4

Photochemical. Ozone

Creation Potential (POCP)

[kg Ethene-Equiv.]

38.53 28.57 38.15 105.26

5 Primary energy demand from

ren. and non-ren. Resources

(net cal. value) [MJ]

14,50,834.09 11,19,062.71 12,37,340.16 38,07,236.97

6 Total freshwater consumption

(including rainwater) [cu.m] 54,093.7 20,238.1 38,931.2 1,13,263.0


Observations

34%

33%

33%

Primary energy demand (38,07,236 MJ)

Process gasBoiler Assembly

Riser & Downcomer piping

Steam DrumGeneralAssembly

35%

30%

35%

Global Warming Potential (2,68,266 kg CO2-Equiv.)





Observations

48%

18%

35%

Total freshwater consumption (1,13,263 cu.m)

Process gasBoilerAssemblyRiser &Down comerpipingSteam DrumGeneralAssembly

76%

4%

19%

0.00 0.5 0%

Material consumption (1,03,956 kg)

Carbon Steel

High DenseAlumina

Low Alloy steel

Stainless Steel

High tensilebolting


Observations

37%

35%

27%

Acidification Potential (AP) assembly wise %[kg SO2-Equiv.]

1150 Kg




34%

29%

37%

Photochem. Ozone Creation Potential break-up % by

assembilies (POCP) [kg Ethene-Equiv.] 105 Kg

Process gas BoilerAssembly


Steam DrumGeneral Assembly


L&T- LCA study results

S.No Parameters

Activities

outside L&T

campus

Activities

inside L&T

campus

Total

1 Acidification Potential (AP)

[kgSO2- Equiv.] 936.47

(81.38%)

214.3 (18.62%)

1,150.77

2 Global Warming Potential (GWP100 years) [kgCO2-Equiv.]

1,42,518.01 (53.13%)

1,25,748.63 (46.87%)

2,68,266.64

3 Ozone Layer Depletion Potential

(ODP, steady state) [kg R11-Equiv.] 0.00 0.00 0.00

4 Photochemical. Ozone Creation

Potential (POCP) [kg Ethene-Equiv.] 80.31

(76.30%)

24.95 (23.70%)

105.26

5 Primary energy demand from ren.

and non-ren. Resources (net cal.

value) [MJ]

20,47,260.62 (53.78%)

17,59,976.35 (46.22%)

38,07,236.97

6 Total freshwater consumption

(including rainwater) [cu.m] 1,13,171.29

(99.92%)

91.71 (0.08%)

1,13,263.0


Recommendations

1. Reduce material consumption by 5%.

2. Material substitution with less resource intensive materials

3. Material substitution with locally sourced materials

4. Increase renewable energy component

5. Reduce absolute energy consumption by 5%

6. Decrease in natural gas consumption by 5%


S.No. Parameters If Weight of material is

reduced by 5%

1 Reduction Global Warming Potential (GWP100

years) [kgCO2-Equiv.]

12,199 (4.55%)

2

Reduction in Primary energy demand from ren. and

non-ren. resources(net cal. value) [MJ]

1,69,658 (4.46%)

3 Reduction Total freshwater consumption(in-clouding

rainwater) [cu.m.]

5,663 (4.99%)

Reduction in weight of material & Environmental Impact

If weight of material is reduced by 5%, the key environmental parameters like

GWP, Primary energy demand & total fresh water consumption for the

process gas boiler system reduces as mentioned in below table:


Replacement of Steel by:

• Advanced high strength plates

• Light weight plates

• Sourcing IS grade materials

Scrap:

Substitution with scrap metal in similar line downstream / upstream

Material substitution


• Consider the public private partnership with locally present steel companies like

Steel Authority of India Ltd. (Bhilai), Essar Steel for developing high strength & light

weight plates.

• Sourcing from L&T Forge shop, Hazira.

Local sourcing of materials


At present, the Powai West campus is sourcing approx. 75% of

total energy demand from renewable sources. Further, if the

percentage of renewable energy over the entire lifecycle is

increased to 90%, the reduction in environmental impacts is

mentioned in table :

Increase in renewable energy sources

S.No. Parameters 90% Renewable

Energy

1 Reduction in Global Warming Potential (GWP100 years) [kgCO2-

Equiv.]

16,025 (5.97%)

2 Reduction in Primary energy demand from ren. and non-ren.

resources(net cal. value) [MJ]

1,60,297 (4.21%)

3 Reduction in Total freshwater consumption(in-clouding rainwater)

[cu.m.]

68,913 (60.8%)


S.No. Parameters

If absolute energy

consumption is

reduced by 5%

1 Reduction in Global Warming Potential (GWP100


1,201 (0.44%)

2 Reduction in Primary energy demand from ren. and


12,016 (0.33%)

3 Reduction in Total freshwater consumption(in-clouding

rainwater) [cu.m.]

5,165 (4.56%)

Reducing absolute energy consumption by 5%

If absolute energy consumption is reduced by 5% the key environmental

parameters like GWP, Primary energy demand & total fresh water

consumption in process gas boiler system reduces as mentioned in below

table:


S.No. Parameters

If Natural Gas

consumption is

reduced by 5%

1 Reduction in Global Warming Potential (GWP100


3,741.5 (1.39%)

2 Reduction in Primary energy demand from ren. and


63,796 (1.67%)

3 Reduction in Total freshwater consumption(in-clouding

rainwater) [cu.m.]

1.5 (~0.01%)

Reducing Natural Gas consumption by 5%

If Natural Gas (NG) consumption is reduced by 5% the key environmental

parameters like GWP, Primary energy demand & total fresh water

consumption reduces by as mentioned in below table:


Reduction in

parameters

If energy

consumption

reduces by 5%

If Natural Gas

consumption

reduced by 5%

Sourcing of Wind

power

(90 %)

If weight of

material is

reduced by 5%

External L&T

In-house External

L&T

In-house External

L&T

In-house Cradle to Gate

Acidification

Potential (AP) [kg

SO2- Equiv.]

0.81 0.19 8.1 1.9 6.48 1.52 58 (5.04%)

Global Warming

Potential (GWP

100 years) [tons

CO2-Equiv.]

638.09 562.91 1,987.59 1,753.91 8,509.27 7,510.92 12199 (4.55%)

Primary energy

demand (net cal.

value) [MJ]

6,462.20 5,553.8 34,309.49 29,486.51 86,207.73 74,089.27 169658 (4.46%)

Total freshwater

consumption

[cu.m]

5,160.87 4.13 1,479.04 1.18 68,857.86 55.13 5663.2 (5.0%)

Recommendations


Benefits of LCA Study

• Demonstrates the ecological performance of the product

• Supports the decision-making during product development

• Helps the Company to revisit and improve its own benchmark

• Provides a business connect


Way forward

Environmental Product Declaration / Eco-labeling

Development of LCA framework

LCA of more products

Gate to grave (end-of-life)


Thank You

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