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Unit Process Life Cycle Inventories CO 2 PE! - UPLCI Workshop Sutardja Dai Hall, Berkeley 23/05/2012 CO 2 PE! - UPLCI Workshop 23/05/12 1
Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
Sutardja Dai Hall, Berkeley
23/05/2012
CO2PE! - UPLCI Workshop
23/05/12
1
Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
1. Welcome and Introduction
Prof. Michael Overcash
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Welcome and Introduction
CO2PE! – UPLCI Methodology
DIN 8580 – Process Taxonomy
Experiences with screening UPLCI
Hands-on session
Integration within LCI-databases
Future action items and Discussion
Overview
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Tens to hundreds of thousands of manufacturing plants (known as transformational steps because these convert materials and chemicals into macro-shape products)
Output of families of products (simple to complex)
Stakeholder expectations
Company has invested in a life cycle understanding of their products
Can provide some form of quantitative environmental footprint of their products
The unit process life cycle inventory (UPLCI) concept has been developed to meet these large global needs of manufacturers and stakeholders
UPLCI is a building block concept to estimate energy and material use at the machine level of a manufacturing plant
For most manufacturing facilities transforming materials or chemicals into industrial or consumer products there are about 120 separate unit processes that are used
Manufacturing Sector Background
Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
2. CO2PE!-UPLCI Methodology
Prof. Joost Duflou
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Sub-Process Level
Optimisation Measures
& Eco-Design Guidelines
Methodology for Systematic Analysis and Improvement
of Manufacturing Unit Process Life Cycle Inventory
Machine Tool Level
Life Cycle Inventory data
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Kellens, K., Dewulf, W., Overcash, M., Hauschild, M., Duflou, J.R. (2012), Methodology
for systematic analysis and improvement of manufacturing unit process life cycle
inventory (UPLCI), Int. Journal of Life Cycle Assessment, Vol. 17/1:69-78.
Methodology for Systematic Analysis and Improvement
of Manufacturing Unit Process Life Cycle Inventory
Guidance for new ISO standard 14955 (Environmental evaluation of machine tools)
Functional Unit:
Quantifies the qualitative and quantitative aspects
of the (main) function(s) of the manufacturing unit
process along the questions “what”, “how much”,
“how well”, and “for how long”
Reference Flow:
1 second of processing time for a specified load
level of a unit manufacturing process for a
specified material based on a working scheme of
2000 hours/year. The system boundaries include
the actual machining modes, as well as the
allocated part of the non-productive modes.
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Critical comparison of methods
Duflou, J.R., Kellens, K., Renaldi, Guo, Y., Dewulf, W. (2012),
Critical comparison of methods to determine the energy input for
discrete manufacturing processes, CIRP Annals, Vol. 61/1.
Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
2b. Case Study - In-Depth Approach
Electrical Discharge Machining
Karel Kellens
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Case study (In-Depth Approach): Electrical Discharge Machining
Standby Mode 9%
Supporting Mode 25%
Operational Mode 66%
standby mode: e.g. process waiting for operator
supporting tasks mode: e.g. workpiece
supporting mode: e.g. clamping, tool change,
tank filling, calibration…
operational mode: e.g. material removal:
roughing and finishing operations
Time Study – Die Sinking
Kellens, K., Renaldi, Dewulf, W., Duflou, J.R. (2011), Preliminary
Environmental Assessment of Electrical Discharge Machining,
18th CIRP LCE2011 Conference, Braunschweig.
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Case study: Electrical Discharge Machining
Die Sinking EDM Wire EDM Power Study
0
0,5
1
1,5
2
2,5
3
3,5
4
Po
wer
[kW
]
Other
Fans & Lightning
Drives
Generator
Pump
0
0,5
1
1,5
2
2,5
3
3,5
4
4,5
5
Po
wer
[kW
]
Other
Fans
Drives
Generator
Filling pump
Filtration pump
Supporting pump
High pressure pump
Pumps are the dominant electrical energy consumers.
Die Sinking EDM: up to 72%, Wire EDM: up to 65%
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Case study: Electrical Discharge Machining
Consumable Study
Die Sinking EDM Wire EDM Micro EDM
Compressed Air 1 l/min (6 bar) 1 l/min (6 bar) 4,8 l/min (6 bar)
Dielectric Hydrocarbon Oil
10 l / week Replacement each year
De-ionized water 10 l / week
Replacement each year
Hydrocarbon Oil 0,45 l / week
Replacement each year
Dielectric filters Replacement every 200 hours
De-ionization Resin / Replacement each year /
Cooling water (10-15°C) 6 l/min 6 l/min 2 l/min
Air filters Replacement every three months
Others Lubrication Oil 0.5 – 1 l / Year
Grease: 250 g/Year Wire Guides
Grease: 100 g/Year Wire electrode for
shaping
Note: Based on a working scheme of 2000 hours/year (250 days with 1 shift)
+ Removed workpiece material (W) as well as the tool electrode wear (T)
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Case study: Electrical Discharge Machining
Emission Study
Based on PhD-Thesis S. Evertz (2003 – RWTH Aachen): Electrical Discharge Machining: exposure assessment using emission and immission based monitoring
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Case study: Electrical Discharge Machining
Impact Assessment
Distribution of the environmental impact during 1 hour of EDM roughing (copper electrode, hard metal workpiece)
Total of ~ 450 mPts
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Process Emissions
0,0%
Dielectric (Production +
EOL) 23,1%
Electrode Material
5,1% Removed Workpiece
Material 1,0%
Energy Consumption EDM Process
47,3%
Energy Consumption
Exhaust System 3,9%
Compressed Air 0,1%
Lubrication 0,1%
Energy Consumption
Process Cooling 19,4%
Case study: Electrical Discharge Machining
Impact Assessment
Electrical Energy and Dielectric main contributors to environmental impact.
Distribution of the environmental impact during 1 hour of EDM roughing (copper electrode, hard metal workpiece)
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Process Models: Framework
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Kellens, K., Renaldi, Dewulf, W.,
Duflou, J.R. (2012), Environmental
impact modeling of discrete part
manufacturing processes, 19th CIRP
LCE2012 Conference, Berkeley.
Process Models: Case study of Laser Cutting
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
3. Process Taxonomy
Prof. Joost Duflou
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Process Taxonomy: Extended DIN 8580
DIN 8580 1. Primary Shaping
2. Forming 4. Joining
5. Coating & Finishing
6. Changing Material Properties 7. Auxiliary Processes
3. Separating
Complete taxonomy overview available in workshop handout
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Current Coverage of Process Taxonomy
Interested to join the Initiative and
cover one or more of the (missing)
processes, don’t hesitate to contact us
and / or place your sticker on this poster.
Barbara Linke
SC
RE
EN
ING
Process Name
Indicate the process name here
Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
4. Experiences with screening UPLCI studies
Prof. Michael Overcash
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Screening UPLCI: Experiences and Future Research
Chemical and material building with transformations to macro shapes
Manufacturing as Transformational Stages
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Screening UPLCI: Examples of the information demand
government (GSA, 2010)
customers (Wal-Mart, 2011)
business-to-business participants
(Environmental Product Declarations, UL, 2011)
product associations (NSF/ANSI, 2009)
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Screening UPLCI: Goals
uplci blocks that are non-complex and transparent.
a fully populated 120 unit process database.
a rapid means of evaluating and supporting decisions for energy improvement of advanced materials, processes, and technology in macro-shape building industry.
add material efficiency, with science-based methods that show direct energy benefits over the whole supply chain, an important innovation.
PET Ethylene glycol Ethylene oxide Ethylene Naphtha Crude Oil0.132 0.044 0.032 0.024 0.02 0.03
Oxygen Air (untreated)0.023 0.033
Water for rxn Water (untreated)0.012 0.012
p-benzenedicarboxylic
acid Acetic acid Carbon monoxide Carbon dioxide Natural gas
Natural gas
(unprocessed)0.113 0.017 0.009 0.004 0.001 0.001
Nitrogen from
air Air (untreated)0.002 0.002
Oxygen from
air Air (untreated)0.001 0.001
Water for rxn Water (untreated)0.001 0.001
Natural gas
Natural gas
(unprocessed)0.003 0.003
Water for rxn
Water
(untreated)0.001 0.001
Methanol Natural gas
Natural gas
(unprocessed)0.009 0.006 0.006
Water for rxn
Water
(untreated)0.004 0.004
Oxygen from air Air (untreated)0.058 0.058
p-Xylene Toluene Naphtha Crude Oil0.073 0.074 0.074 0.077
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Material Supply Chains look like this:
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Life cycle of manufacture pump
ENERGY OR
CHEMICAL LOSS
AMOUNT UNITS
PRODUCTION
ENERGY
930 MJ/PUMP
TRANSPORT ENERGY 36 MJ/PUMP
AIR EMISSIONS 58 KG/PUMP
WATER EMISSIONS 0.01 KG/PUMP
SOLID WASTES 9.3 KG/PUMP
TOTAL CHEMICAL
LOSSES
67 KG/PUMP
High production system basis.
90:10 rule is critical.
All unit process blocks need reasonably close similarity in order to construct higher order manufacturing systems – LEGO® Principle.
Generic UPLCI data build from a common framework for each unit process.
Connect transformation LCI to supply chain LCI.
Allocation is an infrequent issue for these transformational plants.
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Screening UPLCI: Creating UPLCI building blocks
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Stages of unit
process
operation power time
material
loss
method of
calculation
full mode
operation X1 Y1 Z
directly product
related
partial full mode
or idle X2 Y2
indirectly product
related
standby X3 Y3 production related
UPLCI data matrix of 7
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Screening UPLCI: Current Status
UplcI Identification MR1 Drilling
MR2 Shearing
MR3 Milling
MR4 Turning
MR5 Punching
MR6 Reaming
MR7 Grinding
MR8 Boring
J1 Gas metal arc welding
J2 Submerged arc welding
J3 Friction stir welding
MC1 Brakeforming
MC2 Injection molding
HT1 annealing
SF1 Coolant application
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Screening UPLCI: Lessons Learned
1) The results are just estimates that are representative (90:10 rule is simple, but hard to transition)
2) A knowledgeable person can create a uplci in about 1-2 weeks of concentrated work
3) Partial and standby time components of the 7 matrix are first riority
4) Transparency is a major benefit in use by others as it establishes what was assumed and how used
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Building from UPLCI database
Casting Spray Painting InspectionCasting Spray Painting InspectionCasting Spray Painting Inspection
Rahimifard, 2010
Overhead (HVAC and Lighting) for Building
integrating process and non-process energies
each unit process has an machine area footprint
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Five plant studies, 25 machines
For each machine obtain area then use regression to get full allocated area
Building from UPLCI database
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Research in connecting UPLCIs
Each unit process changes the properties of the workpiece that affect the cumulative energy
shape
mass
surface properties
Each block is energy and mass loss per unit of unit process output (so for each step there is a basis change)
This concept of connection is a major part of a user interface
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Life cycle energy profile of transformations by unit processes to make a product
0
5
10
15
20
25
30
35
0 1 2 3 4 5 6 7 8
CTG Level
Nat
ura
l Re
sou
rce
En
erg
y, M
J/o
utp
ut
wo
rkp
iece
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Test Bed Research
The behavior of 3-10 unit processes in sequence or recycle loops is more
than the characteristic of the single UPLCI
Studies of aggregate and individual UPLCI field data (energy and mass
utilization) – test the system behavior
Known as verification and improvement
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Longer term UPLCI research for transformation manufacturing
plants or corporate developments
Alternative manufacturing plant sequences
Process and non-process energy estimations
Coupling with materials and chemicals supply chain
User interfaces
Integrating with use and end-of-life phases (impact of recycling and reuse)
Simulation
Optimization
Comparative analysis of new technology
Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
4b. Panel Discussion
Dr. Barbara Linke, Prof. Fu Zhao
Prof. Karl Haapala
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
4c. Industrial Collaboration
Society of Manufacturing Engineers
Kathy Looman, Prof. Michael Overcash
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Goals
1. Introduce and facilitate use in manufacturing plants to UPLCI tools that estimate energy and mass utilization
2. Utilize industrial expertise to review and support unit process studies (in-depth and screening)
3. Test the UPLCI tools on sequences of machines in high production facilities
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Industrial Technical Communities
Plastics, Composites & Coatings
Automated Manufacturing & Assembly
Industrial Laser
Forming and Fabricating
Product & Process Design and Management
Rapid Technologies and Additive Manufacturing
Machining and Material Removal
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Path Forward
Technical paper to all members
Planning for webinar
On screening UPLCI
On in-depth UPLCI
Pont of contact in each of the technical groups
Review UPLCI studies
Concept of test beds
Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
5. Coffee Break
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
6. Hands-on Session
Karel Kellens and Renaldi
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Hands-on session
Group Work: Small groups of 4/5 persons based on taxonomy
Discussion on processes within process taxonomy
Select 1 to 3 processes within your taxonomy category
Process inputs/outputs ?
Production modes ?
Process parameters ?
3 questions in preparation of the discussion session (last agenda point)
What are the challenges of both CO2PE-UPLCI approaches ?
How can industry be actively involved in this effort ?
Which funding initiatives could be useful in support of collaboration
between partners within the CO2PE!-UPLCI effort ?
Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
7. Integration within LCI databases
Prof. Wim Dewulf
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Tool for Life Cycle Inventory (LCI) data submission
Unit Process Life Cycle Inventories
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7. Integration within LCI databases
Data Input
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DIN 8580 Taxonomy
Process identification
Meta data
Sub-studies
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ISO 14955
Production modes
ISO 14955
Machine functions
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Production modes
Machine functions
Power study
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External
LCI data
Consumables
study
Production
modes
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External
LCI data
Emissions study
Production
modes
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External
LCI data
Production
modes
Waste streams
to technosphere
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
7. Integration within LCI databases
Data export
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Exchanges: overview of the flows from eco- as well
as techno sphere to the unit process and vice versa.
Allocation: where relevant, procedures and
allocation factors for exchanges of multi functional
unit processes should be described.
Process information: description of the reference
unit (functional unit), time period, geography,
technology and dataset information.
Modeling and Validation: describes the
representativeness of the data set, sources (e.g.
literature) and validations (e.g. reviewers)
Administrative Information: documents involved
persons, originator and the published source of the
dataset.
CO2PE! – UPLCI Database
Single Unit Process LCI records
ISO 14955 Report
Aggregated records
EcoSpold data format
Source: http://www.ecoinvent.org
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Tool output
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Dissemination channels targeted
Single Unit Process LCI records
CO2PE! – UPLCI Database
Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
8. Future action items and Discussion
Prof. John Sutherland, Prof. Janet Twomey
Prof. Jacqueline Isaacs
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Feedback on the major concepts, improvements, and potentially missing elements of the two CO2PE-UPLCI efforts.
Industrial participation concepts and collaboration.
How specifically will the audience participate and what funding initiatives might arise to help with the CO2PE-UPLCI effort.
Future Action and Discussion
Discussion
Thank you for your attention!
Questions ?
Remarks ? Suggestions ?
Comments ?
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