Life Cycle Inventory Databasefor Glass Industry
~ Japanese Experience ~
Tooru KudoASAHI GLASS Co., Ltd.
Flat Glass Japan/AsiaCorporate Social Responsibility Center
Environmental & Safety Group
Special Seminar“LCI/LCA in Thailand : 5-year experience under GMTAP”
5, Feb., 2008
Glass for TomorrowGlass for Tomorrow
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP2
Contents
1. Life cycle & Boundary of Flat Glass2. LCA Sample 1; for New Product3. LCA Sample 2; for New Technology4. Conclusion ~ For Planet Earth
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP3
Contents1. Life cycle & Boundary of Flat Glass
i. Raw material stage ii. Production stageiii. Fabricating stageiv. Transporting stagev. Usage stage and Discharging stage
2. LCA Sample 1; for New Product3. LCA Sample 2; for New Technology4. Conclusion ~ For Planet Earth
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP4
1. Life cycle & Boundary of Flat Glass
Air pollution
(CO2, NOx)
Water pollution
(BOD,COD)
Solid wasteetc.
Flat Glass Production
Repairing
Recycle
Discharge
Energy
Raw materials
Wateretc.
Float glass
TemperingSputteringDouble Glazing,
Input Output
Transporting
Construction/Assembling
Fabricating
UseOther Industries
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP5
1. Life cycle & Boundary of Flat Glass~ Consumption ~
Soda ash
Dolomite
Raw materials2.6 x 106 ton
Silica sand38%
11%10%
Cullet36%
SiO2
Na2CO3
CaCO3, MgCO3
Others~5%
Scrap Glass
Flat Glass Products; ~1.4 x 106 ton/year in JapanData source; FLAT GLASS MANUFACTURERS ASSOCIATION OF JAPAN
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP6
1. Life cycle & Boundary of Flat Glassi. Raw material stage ~ Mining & Refining ~LCI of Raw Material Mining & Refining Process
Data Source; “How-to LCA=「LCA実務入門」3. Case study of LCI for Container glass
rate
Consumption ***/ton Air emissionRawore
Elect-ricity
Dieseloil
Heavyoil
NaturalGas Water CO2 SOx NOx
ton kWh ℓ ℓ kg ton kg kg kgSilica sand 38% 1.6 17.5 1.3 12.5 13 0.02 0.01
Soda ash 11% 1.8 142.5 123.3 0.9 353 1.26 0.03Dolomite 10% 1.0 11.6 0.4 2.7 0.1 15 0.05 0.05
Cullet 36% Most of cullet are treated inside glass production plant.included in production stage
kg/ton
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP7
1. Life cycle & Boundary of Flat Glassi. Raw material stage ~ Transporting ~LCI of Raw Material Transporting Process
Data Source; “How-to LCA=「LCA実務入門」3. Case study of LCI for Container glass
Soda ash
Silica sand
Method
Truck Rail Bulkcarrier
Silica sand 433
2780
8640
Soda ash 14400Domestic* 362
Distance / km Consumption Air emissionDiesel
oilHeavy
oilCO2 SOx NOx
ℓ/ton ℓ/ton kg/ton9011 21
0.63 358.9
10523
0.22
0.380.00
0.11
0.100.02
rate
38%
11%15%
Summarize~ CO2 emission of raw material stage ~
0.16 CO2-ton/glass-ton
* Domestic; Dolomite, Limestone, Feldspar, Salt cake, Iron oxide,…
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP8
1. Life cycle & Boundary of Flat Glassii. Production stage
Soda ash
Dolomite
Raw materials2.6 x 106 ton
Silica sand38%
11%10%
Cullet36%
SiO2
Na2CO3
CaCO3, MgCO3
Others~5%
Scrap Glass
CO
Data source; FLAT GLASS MANUFACTURERS ASSOCIATION OF JAPAN (2005)
2 emission at production stage; ~1.74 x 106 CO2-ton/yearProduction amount of Flat Glass; ~1.40 x 106 ton/year
Heavy Oil75%
Electricity
21%
Gasses 4%
Fuel260 PJ
1.51 x 106 CO2-ton
Soda ash
Dolomite
Raw materials2.6 x 106 ton
11%10% Na2CO3
CaCO3, MgCO3
CO2 emission through decomposition of carbonates= 0.23 x 106 CO2-ton
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP9
1. Life cycle & Boundary of Flat Glassii. Production stageSummarize of Environmental Aspects at Production stage
Unit emission per 1 ton of glass product
CO2-ton SOx-ton NOx-ton1.24 0.003 0.005
CO2 emission of raw material stage 162 CO2-kg/glass-ton
CO2 emission of Flat Glass at the outlet of its factory= 1.4 CO2-ton/glass-ton
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP10
1. Life cycle & Boundary of Flat Glassiii. Fabricating stage
Fabricating-Cutting-Beveling-Tempering-Sputtering-Laminating-Double glazing-…
There is no disclosed dataof energy consumption.
• Main energy source is electricity.• The environmental Impact at these fabricating stage are smaller than those of production stage.
Consumption Air emissionCoal LNG Crude CO2 SOx NOx PM53 51 24 7.3x102 0.32 0.88 0.09
LCI of Double glazing process; kg/glass-ton
Data source; TOSTEM “Environmental and Social Report 2004”Presenter edited. Half of flat glass production stage
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP11
1. Life cycle & Boundary of Flat Glassiv. Transporting stage
Flat Glass Plant
500km
1000kmAssumption;•Average transporting distance;Σ(Di x Hi / Ht ) = 394km
Di; distance between prefectural capital and plantHi; new housing units construction of i-prefectureHt; total new housing units construction
•Means of transport; 10ton truck•Carry efficiency; 60%•Fuel; diesel oil•Fuel consumption; 3.5km/l
Small environmental Impactat transporting stage
CO2 emission of transporting stage= 0.05 CO2-ton/glass-ton
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP12
1. Life cycle & Boundary of Flat Glassv. Usage stage and Discharging stage
Air pollution
(CO2, NOx)
Water pollution
(BOD,COD)
Solid wasteetc.
Flat Glass Production
Repairing
Recycle
Discharge
Energy
Raw materials
Wateretc.
Float glass
TemperingSputteringDouble Glazing,
Input Output
Transporting
Construction/Assembling
Fabricating
UseOther Industries
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP13
1. Life cycle & Boundary of Flat Glassv. Usage stage and Discharging stage
LCA; Its objectives are mainly to compare some optionsabout those environmental phase.
I show some sample of LCA about Flat Glass Products.
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP14
Contents
1. Life cycle & Boundary of Flat Glass2. LCA Sample 1; for New Product
~ LCA for “Eco-Glass” ~3. LCA Sample 2; for New Technology4. Conclusion ~ For Planet Earth
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP15
2. LCA for Eco-glass ~ Explanation of products ~
• What is “Eco-glass”?– High performance double glazing unit with
Low-E coated Glass for architectural useLow-E coating;Special metallic coating layer
Insulate Solar heat effectively
Prevent to escape “Warmth” with low thermal transmittance
Summer
Winter
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP16
2. LCA for Eco-glass ~ Objectives of LCA ~
Is “Eco-glass” really effective for global warming?– Its environmental burden is big.
• Twice amount of glass• Other material ( aluminum spacer, sealing material)• Complicated producing process
– It means quality loss at each process.– It means an additional transporting process.
We need to explain for our customer its environmental advantage by LCA
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP17
2. LCA for Eco-glass ~ Boundary ~
• Compare with– Current situation; Normal double glazing or
Single pane window with aluminum sash– “Eco-glass”; Low-E coated double glazing unit
• Compared inventory– CO2 emission
• Inventory data of each material– Flat Glass;
• Raw materials & Transporting process“How-to LCA=「LCA実務入門」 3. Case study of LCI for Container glass
• Production process for Flat Glass & Double glazing unitActual performance data of AGC group
– Other materials ( Sash, Spacer and Sealing materials )• LCA database of JEMAI
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP18
2. LCA for Eco-glass ~ Usage stage ~
How do we evaluate an environmental impact at usage stage?– based on data from Energy Conservation Effect by Insulating
Residential Windows—CO2 Emission Reduction by Using Low-E insulating double glazing (simulation with SMASHsoftware), a publication issued by the Flat Glass Manufacturers Association of Japan in March 2003.
(Source: Flat Glass Manufacturers Association of Japan website)
Ex.) *Controlled room temperature by air conditioner ;20℃ in winter, 26℃ in summer
* Season model of Tokyo; Summer; 22, June ~ 19, Sep., Winter; 2, Nov. ~ 22, Apr.
* Controlled time; 7AM ~ 23PM, ventilating every 2~3 hours
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP19
2. LCA for Eco-glass ~ House Model ~
Floor area / ㎡ 147.40ground-floor 81.15second-floor 66.25
Opening area / ㎡model 1 34.30model 2 41.44
Model 1; for cold regionModel 2; for warm region
Sample of model for single-family house
We use a model for complex housing also.
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP20
2. LCA for Eco-glass ~ Climate Model ~Compared model for each climate model
Ⅰ Low-E-FL3+A12+FL3 Plastic sashⅡ,Ⅲ FL3+A6+FL3 Aluminum sashⅣ~Ⅵ FL3 (single pane) Aluminum sash
Ⅰ~Ⅳ Low-E-FL3+A12+FL3
Ⅴ,Ⅵ Low-E-FL3+A12+FL3(heat shielding type) Ⅱ
Ⅲ
Ⅳ
Ⅴ ⅥⅢ
Ⅰ
Base
ModifiedPlastic sash
Plastic sash
N
Cold area-subfrigid zone-
Hot area-subtropic zone-
Warm area
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP21
2. LCA for Eco-glass ~ Calculation Result ~
Number ofhouses CO2-kg/single house
Single-family house 559,720 393 701
Complex housing 644,460 245 245
Amount of CO2 emission cut10
3ton/yearx
Ⅰ Low-E-FL3+A12+FL3 Plastic sashⅡ,Ⅲ FL3+A6+FL3 Aluminum sashⅣ~Ⅵ FL3 (single pane) Aluminum sash
Ⅰ~Ⅳ Low-E-FL3+A12+FL3Ⅴ,Ⅵ Low-E-FL3+A12+FL3
(heat shielding type)
Base
ModifiedPlastic sash
Plastic sash
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP22
2. LCA for Eco-glass ~ Calculation Result ~
Increased amount of CO2 at production stage &Integrated amount of CO2 emission cut per single house
-5
0
5
10
15
20
0 5 10 15 20 25Elapsed years
CO
2-to
n/ s
ingl
e ho
use
[Inte
grat
ed c
ut C
O2]
–[In
crea
sed
CO
2pr
oduc
ing
stag
e]
-2
-1
0
1
2
3
4
0 1 2 3 4 5
A lot of CO2 emitted at producing can get back by the energy conservation effect in 1~2 years.
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP23
Contents
1. Life cycle & Boundary of Flat Glass2. LCA Sample 1; for New Product3. LCA Sample 2; for New Technology
~ LCA for glass recycling from ELV ~4. Conclusion ~ For Planet Earth
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP24
3. LCA for glass recycling from ELV~ Background ~
ELV;= End Life of Vehicle– 4~5 million unit of vehicle
are dismantled in Japan.– ~40kg of glass/unit– In years go by, glass was
land-filled as one of shredder residue.
We needed to develop recycling method of glass from ELV by considering its environmental advantage by LCA.
Iron 64%Plastics
9%
Glass 4%
Aluminum7%
Composition of ELV
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP25
3. LCA for glass recycling from ELV~ Production stage ~
Gasses3%
Carbonates13%
Heavy oil65%
Electricity18%
COCO22 Emission
1.74x106ton/y
17%0.3x106
ton
Caused by raw materialcan decrease by using cullet
CO2 emission at production stage in Japan
Reactionheat
There is a possibility that we can decrease CO2emission by increasing cullet ratio through recycling of glass from ELV
Soda ashDolomite
Raw materials
Silica sand38%
11%10%
Cullet36%
Others~5%
Scrap Glass
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP26
3. LCA for glass recycling from ELV~ Melting Energy ~
1000
1400
1800
2200
2600
3000
0 20 40 60 80 100Cullet ratio Wt%
Mel
ting
Ener
gy M
J/G
lass
-ton
20
30
40
50
60
70
Hea
vy O
il C
onsu
mpt
ion
l/Gla
ss-to
n
Melting EnergyHeavy Oil Consumption
Cullet ratio & Melting Energy-C. Kroger et al., Glastech. Ber., 26, 202 (1953)-
:
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP27
Silicasand
Soda Dolomite
ash
Cullet
Silica sand
Soda ash
DolomiteCullet
3. LCA for glass recycling from ELV~ Target ~
Current situation
Land-fill
ELV
shredder
100
100
Target
Sorting / Washing
ELV
Dismantle of Glass
Cullet recycle
Land-fill
shredder
70
67
303
Separating Technology •Laminated glass•Black enamel
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP28
3. LCA for glass recycling from ELV~ Inventory ~
•Recycling Process•We developed and constructed a test facility.•We gathered the inventory data through recycling test.
Tomakomai
Sendai
YokohamaNagoya
Kitakyusyu
•Recovery Process for ELV cullet•ELV Dismantle trader at each prefectural capital
5 accumulation place by truckTomakomai, Sendai, Yokohama, Nagoya, Kitakyusyu
recycling plant in flat glass factory by bulk carrier near Nagoya
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP29
3. LCA for glass recycling from ELV~ Result ~
-2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5
CO2 emissionReduce Increase
Current situation
Target situation
Transporting
ShreddingLand-fill
Recycle Process
Expected amount of CO2 emission cutWe can reduce raw material mining, also.
Increased part
Melting Process
Reduced part
Transporting
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP30
Contents
1. Life cycle & Boundary of Flat Glass2. LCA Sample 1; for New Product3. LCA Sample 2; for New Technology4. Conclusion ~ For Planet Earth
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP31
4. Conclusion ~ For Planet Earth
1. Glass industry use relatively large amounts of resources and energy.
Ex. ~1.2 ton-CO2 emission / Glass 1ton
2. But glass industry can propose and offer Eco-friendly products in their Life cycle.Ex. Eco-glass (Low-E coated double glazing)
3. We should develop new products and new technology for planet earth through LCA. Especially, against for global warming issue that is urgent common problem for all over the world.
4. We should explain to our customer about LCI of our products through logical LCA.
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP32
END
Thank you for your attention!
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP33
How did we gather our inventory data?
• Reporting obligation– for research of industry dynamic state
to Ministry of Economy, Trade and Industry• Reporting contents
– consumption of raw material and energy source ( Oil, Gas & Electricity )
– manufacturing quantity• Reporting path
– Industry group, Flat Glass Manufacturers Association of Japan, gathers, tallies up and reports.
⇒So, Flat Glass Manufacturers Association of Japan has already gripped its inventory data.
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP34
History of LCA -Beginning-
• AGC got a certification of ISO14001 in 1998 Feb.(next year of COP3 )
• In that time, I worked in R&D center of AGC.• We considered;
– What kind of activity of R&D will be useful to improve Environment impact?
• We concluded;– We should evaluate an environmental impact of our
developing products & production technologyand we should contribute to a sustainable society
• We made a plan to introduce LCA concept in the evaluation process of R&D theme.
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP35
History of LCA - Applications -• LCA for Eco-Glass;1997~
– SMASH program had been investigated already at Tokyo University.– An energy saving effect of several building materials was evaluated
using by SMASH program when Ministry of land, infrastructure andtransport of Japan made “Energy Saving Guideline for Future Generation Housing”. In that time, Flat Glass Industry cooperated in this project.
– LCA for Eco-Glass takes root in society in Japan gradually. We can appeal this result of eco-friendly performance of Eco-Glass at its sales.
• LCA for Glass recycling from ELV;2001– An automotive maker assessed LCA for new technologies of
automotive industry with cooperating of several element makers. AGC cooperated in this project ( Ex. Glass Recycling from ELV ).
• Others– LCA for Cover Glass of Solar module; 2007– LCA for recycling process of laminated glass, solar module;
2002~2007
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP36
Contents1. Introduction of ASAHI GLASS Co., Ltd.2. Life cycle & Boundary of Flat Glass3. LCA Sample of Flat Glass Products4. Conclusion ~ For Planet Earth
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP37
Contents1. Introduction of ASAHI GLASS Co., Ltd.
i. Business domainii. Company of AGC Groupiii. Group Vision iv. Environmental performance
2. Life Cycle & Boundary of Flat Glass3. LCA Sample of Flat Glass Products4. Conclusion ~ For Planet Earth
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP38
Account date: Dec., 2006
Board of Meeting/Management Committee
Flat Glass Company ; \ 515 Billion
Automotive Glass Company ; \ 301 Billion
Display Company ; \ 318 Billion
Chemicals Company ; \ 308 Billion
Electronics & Energy Company ; \ 162 Billion
We are committed to finding out just how pleasant glass can make life..
Our pursuit of safety led to this sophisticated glass.
Ensuring the biggest, brightest and most beautiful images
Technology developed in glass production is at work on the frontiers of electronics.of electronics.
Our commitment to pioneering new applications is expanding the envelope for new materials and performance chemicals.Others( Ceramics, Biochemical,… ) ; \ 84 Billion
Total Sales; \ 1,621 Billion
Allianz-Arena
1. Introduction of ASAHI GLASS Co., Ltd.i. Business domain
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP39
1. Introduction of ASAHI GLASS Co., Ltd.ii. Global Evolution
North America Europe Asia Japansubsidiary 27 98 44 AGC + 54
plant 20 55 27 77sales \ billion 205 366 436 9,130
employee 6,500 16,800 16,200 14,800
・ Main production; 23 countries
since 1952
since 1963
since 1981
since 1992
since 1907
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP40
1. Introduction of ASAHI GLASS Co., Ltd.ii. Global Evolution
AGC Flat Glass (Thailand) Co.,Ltd.Samut Prakan PlantChon Buri PlantRayong Plant
AGC Automotive Thailand Co.,Ltd.Bangpakong Plant Samut Prakan Plant
AGC Electronics (Thailand) Co., Ltd.Ayuttaya
ราชอาณาจกัรไทย
AGC Chemicals (Thailand) Co., Ltd. Bangkok Samut Prakan Plant A, BRayong Plant
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP41
1. Introduction of ASAHI GLASS Co., Ltd.iii. Group Vision
OurMission
Our Shared Values
Our Objectives
Our Principles
To make the world a brighter placeInnovation & Operational Excellence
Diversity
Environment
Integrity
【革新と卓越】
【多様性】
【環境】
【誠実】
Since 2002
We, as good global citizens, will shoulder the responsibility to contribute to a sustainable society in harmony with nature.
Environment
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP42
1. Introduction of ASAHI GLASS Co., Ltd.iv. Environmental performance - GHG -
GHG: Global Greenhouse GasGHG emission of AGC Japan
Fluorinated GHG emissions
CO2 emissions
CO2/sales of Asahi Glass Japan
Mill
ion
CO
2-to
n of
GH
G
10 to
n C
O2/m
illio
n ye
n
96% reduced!
27%reduced!
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP43
1. Introduction of ASAHI GLASS Co., Ltd.iv. Environmental performance - Wastes -
Waste sent to Landfills of AGC Japan
Recycle ratio
Land
fill a
mou
nt 1
000-
ton/
year
Rec
ycle
ratio
%
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP44
Contents1. Introduction of ASAHI GLASS Co., Ltd.2. Life cycle & Boundary of Flat Glass
i. Raw material stage ii. Production stageiii. Fabricating stageiv. Transporting stagev. Usage stage and Discharging stage
3. LCA Sample of Flat Glass Products4. Conclusion ~ For Planet Earth
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP45
Contents1. Introduction of ASAHI GLASS Co., Ltd.2. Life cycle & Boundary of Flat Glass3. LCA Sample of Flat Glass Products
i. LCA for Eco-glassii. LCA for glass recycling from ELV
4. Conclusion ~ For Planet Earth
5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP46
Contents1. Introduction of ASAHI GLASS Co., Ltd.2. Life cycle & Boundary of Flat Glass3. LCA Sample of Flat Glass Products4. Conclusion ~ For Planet Earth