Docsity Environmentally Conscious Manufacturing Lecture Notes Ie 5390

Environmentally Conscious
Manufacturing - Lecture
Notes | IE 5390
Engineering
University of Texas - El Paso
59 pag.
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IE 5390/IE4395 Special Topic:
Environmentally Conscious (Benign)

Manufacturing
Gabi v. 4 User Manuals

for Photocopier Example
© Copyright Tzu-Liang (Bill) Tseng, 2006. All rights reserved. 1

Table of Contents
1. Introduction………………………………………………………..……..3
1.1 Conducting the LCA

1.2 Goal & Scope Definition: ISO 14040
1.3 Goal & Scope Definition: Using GABI
2. Photocopier LCA…………………………………………………..……...7
2.1 The Final Model.

2.2 The Recycling Model
2.3 The Use Model
2.4 The Manufacturing Models
3. Life Cycle Impact Assessment………………………………………….41
3.1 Screening A Balance Result

3.1.1 Mass Balance View
3.1.2 Energy View
3.2 Dominance Analysis
3.3 Characterization, Normalization and Evaluation
3.3.1 Characterization
3.3.2 Normalization
3.3.3 Evaluation
4. The GABI4 Analyst…………………………………………………… 53
4.1 Parameter Variation.

4.2 Scenario Analysis
4.3 Monte Carlo Analysis
5. Categorization………………………………………………………… 56
6. Allocation………………………………………………………………60

1. INTRODUCTION:
You are a Manufacturing Engineering in-charge of conducting a LCA study about Photocopier
super copy XR-2. You have a costumer who wants a photocopier but, he is concerned about the
effects of the Photocopier on the environment. So you need to convince him that the photocopier
is environmental friendly and show him how to dispose some of the components that are used in
the photocopier. The name of the Product is “Photocopier Supercopy”. The results will not be
published.
Now narrowing down on what can be recycled or how to dispose some of the components are
considered,
1. Disposable Toner
2. Disposable and recycling printed paper
3. Disposable Drum
Now to economize the distance and the fuel consumed for traveling we consider all the
disassembly unit, reassemble units and remanufacturing units are situated at a distance of 50km
from each other. By using different principles of LCA you have to justify your model and show
your model is friendly to the environment. The required assumptions can be made. There is
nothing like a standard answer so try to give best justification of your results.
All the design and analysis must be made in the GABI4 software

1.1 Conducting the LCA:
Start
First Goal and Scope

(GaBi software) Calculating the balances
(GaBi Software)
Modeling the Product

System Screening the balance
results
(GaBi Software)
Data collection
(GaBi Software) Dominance Analysis
(GaBi Software)
Modeling the System

“Photocopier” Single Score Evaluation
(GaBi Software)
End

1.2 Goal and Scope Definition: ISO 14040
The Goal definition shall unambiguously state:

1. The intended application.
2. The reason for carrying out the study and
3. The intended audience.
These goals statements shall be the basis for defining the questions to be addressed by the study
The Scope of a LCA describes the model of the system to be studied.
Linking the goal and scope definitions: The process of defining the scope of a study must always
be directly related to the goal: The scope should be defined well enough to ensure that the
breadth and depth of a study are compatible with and sufficient to address the stated goal.
Scope definition is an iterative process (elements of the initially defined scope have to be
reviewed and in practice often be revised). If the scope needs to be revised, ensure the definition
is still directly linked to the goal. If not the goal definition must be revised.
Elements of scope definition according to ISO:
• The function of the system(s);
• The functional unit;
• The system to be studied;
• The system boundaries;
• Cut-off criteria;
• The allocation procedures;
• The type of impact assessment;
• The methodology of impact assessment;
• Data requirements;
• Assumptions;
• Limitations;
• The initial data quality requirements;
• Type of critical review, if any and;
• The type and format of the report.
1.3 Goal & Scope Definition: Using GaBi


First, in the database manager, make a copy of your educational database “CopierDB” and name
it “SuperCopy XR-2”. Then right click on your SuperCopy XR-2 database and select “active”
from the menu. Now, right click on your “CopierDB” and select “disconnect”. This will protect
the integrity of your educational database. In the database manager, select “new”. This will open
a blank window, similar to the one you see above. Here, enter the qualitative information about
the study. If you leave this window minimized during your work on this project in this database,
a record will be kept of the objects you use and create during the study.
2 LIFE CYCLE OF PHOTOCOPIER SUPERCOPY XR-2:


2.1 The Finial Model
The processes involved in this plan are
MANUFACTURING SUPERCOPY XR-2

UTILIZATION SUPERCOPY XR-2
END OF LIFE SUPERCOPY XR-2
DISPOSAL TONER
DISPOSAL AND RECYCLING PRINTED PAPER
DISPOSAL DRUM
2.2 The Recycling Models


Starting with No. 6 “DISPOSAL DRUM”
To build the Disposal drum Recycling process plan we require:

• Drum (used) disassembly
• Diesel fuel
• Transport (long distance)
• Gas and Steam power plant
• Steel billet (electric furnace)
• Steel billet
• Waste incineration plant (municipal waste)
• Waste incineration plant (plastics)
The required process and the flows can be dragged and dropped on to the plan. If any process or
flow is missing then we have to create according to the data available.
The figure below shows the details of a process that must created.

Details of Drum (used)

In the database manager, in category waste for recovery, right click on the right side of the DB
Manager to create a new unit process. Fill in the information as shown in the screen shot above.
You will need to create a new flow here called Steel scrap (St). To do so switch to the DB
Manager and crate it in the flow hierarchy in the waste for recovery category. Right click and
select new from the menu. Complete the new flow as shown in the figure below. Then close the
new flow and switch back to your unit process to enter the new flow.
Properties of Drum (used)

Complete the plan by connecting the unit processes and fixing the Drum disassembly process to
one. Fixing a processes can be done be double clicking on the process itself, and entering a “1”
in the Scaling Factor box and ticking the checkbox marked Fixed.
5.1 Recycling printed paper


The processes we require for Recycling printed paper as follows:
Waste paper disposal

Power Grid
Thermal energy for natural gas
Transport (long distance)
Diesel fuel
Waste paper recycling

Details
As mentioned above create a new flow called Water (feed water) in water of the flow hierarchy

And the Properties of the Waste paper recycling are as follows:
Now creating the next plan Disposal and recycling printed paper No. 5 in Recycling

The processes we require for Disposal and Recycling Printed Paper are as follows
Diesel fuel
Fibers (paper) from wood
Paper return
Recycling Printed Paper
Plan No: 4 “Disposal toner”

The processes we require for Disposal toner are as follows
Toner cartridge disassembly
Diesel fuel
Waste incineration plant
Gas and steam power plant
Details of Toner Cartridge (Empty) Disassembly


Properties of toner cartridge (empty) disassembly

NO: 3 “End of Life SuperCopy XR”

The processes we require End of Life SuperCopy XR- for are as follows
• Diesel fuel
• Transport (local)
• Thermal energy from natural gas
• Power Grid
• Drawer disassembly
• Case plastic parts
• Disassembly mechanical parts
• Electronic part disassembly
• Case metal parts disassembly
• Toner cartridge disassembly
• Plastic recycling
• Waste incineration plant (municipal waste)
• Disposal electronics scrap
• Steel billet (electric furnace)
• PC/ABS compound
• Gas and steam power plant
• Steel billet (inv).

Now we are going to create processes for all listed below
a) Drawer disassembly

Details

Properties

b) Case plastic parts disassembly
Details
Here we are now introducing a new concept called Parameters and the box bellow shows how to
activate it
Just click on the part that is circled in the tool bar and your parameter window will be activated.

And the Properties of the created process are as follows
Properties

c) Disassembly mechanical parts
Details

Properties

d) Electronic parts
Details

Properties

e) Case metal parts disassembly
Details

Properties

f) Toner cartridge (empty) disassembly
Details

Properties

g) Drum (used) disassembly
Details

And the Properties of the created process are as follows
Properties

2.3 The Use Model
Create the Plan no.2: The Utilization SuperCopy XR-2
The processes and flows required for the this plan are
• Drum photocopier
• Toner cartridge photocopier
• Paper (wood free; uncoated)
• Power Grid
• Diesel fuel
• Utilization SuperCopy XR-2

2.4 The Manufacturing Model
Create Plan no.1: The Manufacturing SuperCopy XR-2
The processes and the flows involved are

• Case photocopier
• Drawer complete photocopier
• (Electro) mechanical parts photocopier
• Electronic parts (active) photocopier
• Electronic parts (passive) photocopier
• Toner cartridge photocopier
• Drum photocopier
• Manufacturing SuperCopy XR-2
• Diesel free refinery

a) Case photocopier
To build the Case Photocopier

• Case Photocopier plastic parts (from the above created plan).
• Case Photocopier Metal parts
• Glass
• Case Photocopier
• Diesel fuel.

Details of case photocopier (b)

Properties

Building the Main Cycle
Once we have created all the Plans and Processes, we need to put all these plans together in one
plan called Life Cycle Photocopier Supercopy XR-2.
Drag and Drop all these Plans in Life cycle Photocopier plan and calculate the balances.

3 LIFE CYCLE IMPACT ASSESSMENT
3.1 Screening a Balance Result

Screening is performed to check the reliability of the results, identify gaps, identifies errors of
data input and to identify errors in system modeling. When screening, the quantities of mass and
energy are often used.
Mass view can be used to screen for errors in system modeling. Typical error in system molding
is unconnected tracked flows on GABI plans. From the balance view they can be found by
analyzing valuable substances/production residues flows (found of the output side of the
balance). As a rule of thumb, no values contribute and from which processes they are released.
The advantage of the energy view is that it shows primary energy demand in the input table
(upper table of the balance window). Primary energy demand is a good indicator for
environmental impacts because the environmental impacts of a product system often correlate to
the primary energy demand of the same product system (however, it must be noted that it does
not fully represent environmental impact). The goal of the screening is to check the actual results
of the assessment against the expectation and background of the user.
Focus on those process steps that constitute the main difference between the potions and check
them individually. Check the relative contributions of the life cycle phases against the total
result. Try to evaluate whether these seem reasonable to you. Check whether one life cycle phase
dominate other to a very large extant (>99%) without obvious reason.
As rules of thumb for evaluating the validity of a balance result, it can be said that:
• The life cycle phases contribute to the following shares: Production 10-15%, Use 50-95%
and End-of-life <5%.
• Material production contributes about 80% and processing of these materials contributes
about 20% the production phase.

Do not blindly trust your results, even if your expectations are fulfilled! IF you find your
expectations are fulfilled you must verify the plausibility of the result.
There are four different energy quantities that must be viewed at
“Energy (net calorific value)” Energy (gross calorific value)”
“Energy ren. (gross caloric value)” “Energy ren. (calorific value)”
Commonly, the Energy (net calorific value) view is used in screening and later on for
evaluating the primary energy demand. This is because the calorific value is used more often
than the gross calorific value in the technical world. If desired, Energy (gross calorific value)
can be used instead. However, it should be made sure that one of these quantities is used
consistently during the assessment. The energy ren. (renewable) views should usually not be
used for screening because they represent the demand of primary energy from hydro power. This
demand does not correlate to environmental impact to a sufficient extent.

3.1.1 Mass Balance View
To view a Mass Balance
1. Select “Mass” at the Quantity drop-down menu.

2. Select level 1 of the process/plan hierarchy. This shows you the comparison of the
product systems (represented by the respective plans).
3. Select level 2 of the flow hierarchy. This gives you a sufficient degree of detail for the
screening (main flow groups):
• Resources
• Valuable substances
• Emissions into air
• Emissions into water
• Emissions into soil
• Deposited goods
• Production residues in life cycle
• Others
(In most studies, some of the flow groups appear either in the input or in the output
table only, some appear in both table)
4. The in/out aggregation box must be activated.
5. Examine the flow groups “Valuable substances” and “production residues in life cycle”.
If values appear finding out which flows contribute to these flow groups.

Examine the groups “Valuable substances” and “Production residues in life cycle”.
By examining all the results carefully we can get an idea of how much of each material is going
in to the process, how much is getting in to the environment, how much is useful, how much is a
waste etc... By close observation we can conclude weather the product we design is ecofriendly
or not if not getting back into the process to see what changes can be made.

3.1.2 Energy View
1. Return to the balance just calculated.
2. Select “Energy (net calorific value)” from the Quantity drop-down menu. This result
shows only energy from non-renewable sources.
3. Select level 2 of the flow group hierarchy.
4. Select level 1 of the process/plan hierarchy.
5. Select “Relative contributions”.
6. Examine “which wins”
7. Look at the contributions associated with cycle phases and compare against the total.
8. Select level 2 of the process/plan hierarchy.
9. Examine where the differences between both life cycles are.
10. Double click the respective column headers to unfold more details and investigate the
contributions of single processes.
11. Unfold the production life cycle phase of the kitchen appliance.
12. Examine the contributions of single processes to the production life cycle phase.

This balance sheet shows us the percentage of the stages contribution to the total life cycle.
For example from the above we observe that out of 100% of the Life Cycle of the Photocopier
SuperCopy XR-2, 7.49% contribution from the Manufacturing phase, 55.7% contribution from
the Utilization phase and 41.038% from the Recycling phase, in this we have 40.4% from the
Disposal and recycling printed paper, 0.00437% from the Disposal Drum, 0.26% of the Disposal
Toner, 0.374% of the End of Life SuperCopy XR-2. So from this we get an idea from which
phase the contribution is more and where the concentration should be more.

3.2 Dominance Analysis
Dominance analysis is performed to identify those stages of the life cycle which contribute most
to factors such as mass and energy. Total primary energy demand is often as an analysis
parameter.
Primary energy demand is a good indicator for environmental impacts because environmental
impacts of a product system often correlate to the primary energy is of the same system
(however, it must be noted that it does not fully represent environmental impact).
Instead of primary energy demand, dominance analysis can be performed using many other
analysis parameters, such as: specific emissions, environmental impacts or single score
indicators.
Method: Dominance Analysis using “Primary Energy Demand”

• Select “Evaluation” at the balance window.
• Select “Energy total (net calorific value)” at the Evaluation drop-down menu. This result
shows the total energy required: non renewable + renewable.
• Select level 2 of the process hierarchy. This gives you three columns besides the column
for the total life cycle:
Production
Use
End of life
• Select “Relative contribution”. The relative contributions of the three life cycles phase
(production, use, end of life) are displayed.
Now we want to investigate the dominant process within the production phase:
• Double-click on the top of the column “production” and examine the contributions of
each unit process.

Conclusions of Dominance Analysis
The Utilization phase of the Photocopier dominates (66.3%) the life cycle with it’s weight of the
copier. Therefore weight reduction is an option to lower down significantly the environmental
burdens of the life cycle.

3.3Characterization, Normalization and Evaluation
The aggregation of impact indicators to a single score is often done for comparison reasons. The
question often is: What is better, option A with a low acidification potential (AP) or option B,
which has a higher AP, but lower GWP compared to option A?
Normalization
Normalization is performed to normalize different indicators to a common reference. For or
example we will choose the reference annual world contribution for the respective indicator. In
practice this means, the impact indicator value of the system being evaluated is divided by the
impact indicator for the world per annum for this impact category.
Evaluation or ‘Weighting’
Evaluation is performed to emphasize the normalized impacts according to their environmental
relevance. There are several approaches and methodologies to evaluation/weighting. Some are
“semi-scientific” by setting up ‘damage’ functions, other are determined using opinion polls.
Single score
Multiplying the normalized impact indicators with the respective weighting factors and then
aggregating the results produces a single score.

3.3.1 Characterization
1. First, calculate a balance that compares the two life cycles.
2. Look at each of the Impact Categories individually- click on “Quantity View” and
deactivate the inputs.

3.3.2 Normalization
1. Deactivate the input side of the balance
2. Select “Global warming potential (GWP 100 years)” at the Quantity drop-down menu
3. Select “Normalization” at the balance window.
4. Select “World” at the Normalization drop-down menu.
This gives you two columns for the considered life cycle displaying the normalized
values for GWP.

3.3.3 Evaluation
1. Reactive the input side of the balance.
2. Select “Experts” at the Evaluation drop-down menu
3. Select “Quantity view” at the balance window
This breaks down the normalized and evaluated values contributing to the single score.
4. Select “Relative contribution”.
The relative contributions of the impact categories are displayed.

4 THE GABI 4 ANALYST
4.1 Parameter Variation

Next we will perform an interpretation using the balance results of the Life Cycle Kitchen
Appliance. In this example it is demonstrated how a change in the average life of a vehicle and
the weight of the Kitchen Appliance is reflected in the balance results. The interpretation uses a
parameter variation to interpret the cumulative energy use for the life cycle in a liner fashion.
The GABI 4 Analyst can be more intensive than in this example.
Create a balance of the Life Cycle Kitchen Appliance plan in the DB Manager and expand the
columns showing to level 2 using the drop down menu located at the far right of the balance.
Then click on the GABI Analyst button in the toolbar. Once the Analyst opens, click on
parameter variation and then click on edit scenario. Choose “Scenario 1” from the drop down
list. Expand Global Parameters and click on Battery Housing the mileage parameter and enter
0 and click Apply on the bottom right corner of the window. The Analyst should now look like
the figure shown above. Then, using the Intermediate Steps drop down menu selects 5 to view
the results in that many intervals. Click on the green arrow on the top right of the window. Now,
select which environmental impact to evaluate using the drop down menus provided. First, select
Outputs from the Balance Table column. Then select the Use phase form the next column and
GWP 100 from the Quantity/Evaluation column and the result will be displayed below.
Additional results can be displayed by following the same steps as above for other environmental
or cost analysis categories.

4.2 Scenario Analysis
The second function of the GABI Analyst is the scenario analyst is which several parameters of a
product system are set to specific values in order to calculate scenarios. Only the number of
parameters defined in the system modeling limits the number of parameters that can be used to
define a scenario.
Create a balance of the Primary Battery Housing plan in the DB Manager and expand the
columns showing to level 2 using the drop down menu located at the far right of the balance. The
click on the GABI Analyst button in the toolbar. Once the Analyst opens, click on scenario
analysis and then click on edit scenario. Choose “Scenario 1” from the drop down list. Expand
Global Parameters and click on Battery Housing Parameters. This provides you with a list of
the global parameters define in the model. Click on the value for the weight parameter and enter
0.3. Then, expand the model tree to find the Automotive Part; Fuel Consumption unit process
parameter and change the fuel_reduction factor to 0.1 and click Apply on the bottom right corner
of the window. The Analyst should now look like the figure below. GABI automatically enters
the data for Scenario 2 the base case.
Click on the green arrow on the top right of the window. Now we will select which
environmental impact to evaluate using the drop down menus provided. First, select Inputs from
the Balance Table column. Then select Energy Overall (Calorific value) from the
Quantity/Evaluation column and the result will be displayed below, as shown in the figure
below. Additional results can be displayed by following the same steps as above for other
environmental or cost analysis categories.
Sensitivity analysis can also be performed in a similar manner, by clicking on the sensitivity
analysis button. In this option you have the ability to vary parameters within a define range to
interpret the sensitivity of your model.

4.3 Monte Carlo Analysis
Now we will use the GABI Analyst to perform to Monte Carlo analysis. Monte Carlo analysis
calculates errors (due to imprecise measurement or wrong data) using stochastic method. The
chosen base scenario is randomly varied between a minimum and maximum limit. The result is a
calculated mean value of the chosen quantity (e.g. GWP) with a standard deviation.
Using the same scenario from our scenario analysis, here the stability of the scenario will be
determined based on error ranges expected from the variable input for this scenario. Looking at
the figure below, the results for this scenario from an approximate bell curve as expected

5 CATEGORIZATION
GABI allows you to categorize your processes and using standard as well as custom definitions.
This is useful, for example, when, analyzing the balance for ISO 14001 purpose or for
Greenhouse Gas Analysis. For ISO 14001, categorization enables you to label unit processes as
internal or external and for Greenhouse Gas Analysis as scope 1, 2 or 3 under the WBCSD
definition for entity analysis. The model can then be analyzed in the balance, comparing
categories of unit processes.
Lets view the Categorization for a one plan. Open the plan for the Life cycle Photocopier and go
to the details for the Disposal Toner.
By double clicking on a process, you open the process instance window. This window is the
same as the window used in changing parameters as seen previously in other example. At the
bottom, you will see several drop down menus.

These drop down menus enables you to qualitatively define the country, type, enterprise and
provide you with the ability to create user defined categories. Using the table below, categorize
each of the unit processes on the plan in both the enterprise and User Defined menus
Process Enterprise User defined

Toner cartridge (empty) External Scope 1
disassembly
Diesel free refinery External Scope 2
Truck External Scope 3
Waste incineration plant External Scope 4
Gas steam power plant External Scope 5

Next, we create a balance of the Life Cycle of the Photocopier SuperCopy XR-2. Select
GWP100 from the quantity menu and choose categories from the drop menu located under the
in/out aggregation checkbox. Here you may filter the results based on the defined categories
from the plan. Choose categories and then tick user-defined. This will enable you to view your
production facilities GHG emissions categorized by scope 1, 2 and 3 as defined by WBCSD.

Using the same process, you can toggle the balance to view external process impacts.


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Environmentally Conscious (Benign)

Gabi v. 4 User Manuals

© Copyright Tzu-Liang (Bill) Tseng, 2006. All rights reserved. 1

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1.1 Conducting the LCA

2.1 The Final Model.

3. Life Cycle Impact Assessment………………………………………….41

3.1 Screening A Balance Result

4. The GABI4 Analyst…………………………………………………… 53

4.1 Parameter Variation.

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First Goal and Scope

Modeling the Product

Modeling the System

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The Goal definition shall unambiguously state:

1.3 Goal & Scope Definition: Using GaBi

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2 LIFE CYCLE OF PHOTOCOPIER SUPERCOPY XR-2:

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The processes involved in this plan are

 MANUFACTURING SUPERCOPY XR-2

2.2 The Recycling Models

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To build the Disposal drum Recycling process plan we require:

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Properties of Drum (used)

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5.1 Recycling printed paper

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 Waste paper disposal

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Plan No: 4 “Disposal toner”

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Details of Toner Cartridge (Empty) Disassembly

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MANUFACTURING SUPERCOPY XR-2

Waste paper disposal