Experiences with the critical review process of aluminium LCI data

Background, aim, and scope  

This paper summarises the critical review process according to ISO 14040/44 performed for the European Aluminium Association (EAA), Brussels. Scope of the review was a life cycle inventory (LCI) project, aiming at providing the life cycle assessment (LCA) community with reliable generic data relevant for the European aluminium market, including the production of aluminium ingot either from primary aluminium or from recycled aluminium and the fabrication of semi-finished products, i.e. sheet, foil or extrusion fabrication from aluminium ingots.     

Life cycle assessment of commercial furniture: a case study of Formway LIFE chair

Background, aims and scope  The environmental aspects of companies and their products are becoming more significant in delivering competitive advantage. Formway Furniture, a designer and manufacturer of office furniture products, is a New Zealand-based company that is committed to sustainable development. It manufactures two models of the light, intuitive, flexible and environmental (LIFE) office chair: one with an aluminium base and one with a glass-filled nylon (GFN) base. It was decided to undertake a life cycle assessment (LCA) study of these two models in order to: (1) determine environmental hotspots in the life cycle of the two chairs (goal 1); (2) compare the life cycle impacts of the two chairs (goal 2); and (3) compare alternative potential waste-management scenarios (goal 3). The study also included sensitivity analysis with respect to recycled content of aluminium in the product. Materials and methods  The LIFE chair models consist of a mix of metal and plastic components manufactured by selected Formway suppliers according to design criteria. Hence, the research methodology included determining the specific material composition of the two chair models and acquisition of manufacturing data from individual suppliers. These data were compiled and used in conjunction with pre-existing data, specifically from the ecoinvent database purchased in conjunction with the SimaPro7 LCA software, to develop the life cycle inventory of the two chair models. The life cycle stages included in the study extended from raw-material extraction through to waste management. Impact assessment was carried out using CML 2 baseline 2000, the methodology developed by Leiden University’s Institute for Environmental Sciences. Results  This paper presents results for global warming potential (GWP100). The study showed a significant impact contribution from the raw-material extraction/refinement stage for both chair models; aluminium extraction and refining made the greatest contribution to GWP100. The comparison of the two LIFE chair models showed that the model with the aluminium base had a higher GWP100 impact than the model with the GFN base. The waste-management scenario compared the GWP100 result when (1) both chair models were sent to landfill and (2) steel and aluminium components were recycled with the remainder of the chair sent to landfill. The results showed that the recycling scenario contributed to a reduced GWP100 result. Since production and processing of aluminium was found to be significant, a sensitivity analysis was carried out to determine the impact of using aluminium with different recycled contents (0%, 34% and 100%) in both waste-management scenarios; this showed that increased use of recycled aluminium was beneficial. The recycling at end-of-life scenarios was modelled using two different end-of-life allocation approaches, i.e. consequential and attributional, in order to illustrate the variation in results caused by choice of allocation approach. The results using the consequential approach showed that recycling at end-of-life was beneficial, while use of the attributional method led to a similar GWP100 as that seen for the landfill scenario. Discussion  The results show that the main hotspot in the life cycle is the raw-material extraction/refinement stage. This can be attributed to the extraction and processing of aluminium, a material that is energy intensive. The LIFE chair model with the aluminium base has a higher GWP100 as it contains more aluminium. Sensitivity analysis pertaining to the recycled content of aluminium showed that use of aluminium with high recycled content was beneficial; this is because production of recycled aluminium is less energy intensive than production of primary aluminium. The waste-management scenario showed that recycling at end-of-life resulted in a significantly lower GWP100 than landfilling at end-of-life. However, this result is dependent upon the modelling approach used for recycling. Conclusions  With respect to goal 1, the study found that the raw-material extraction/refinement stage of the life cycle was a significant factor for both LIFE chair models. This was largely due to the use of aluminium in the product. For goal 2, it was found that the LIFE chair model with the aluminium base had a higher GWP100 than the GFN model, again due to the material content of the two models. Results for goal 3 illustrated that recycling at end-of-life is beneficial when using a system expansion (consequential) approach to model recycling; if an attributional ‘cut-off’ approach is used to model recycling at end-of-life, there is virtually no difference in the results between landfilling and recycling. Sensitivity analysis pertaining to the recycled content of aluminium showed that use of higher recycled contents leads to a lower GWP100 impact. Recommendation and perspectives  Most of the GWP100 impact was contributed during the raw-material extraction/refinement stage of the life cycle; thus, the overall impact of both LIFE chair models may be reduced through engaging in material choice and supply chain environmental management with respect to environmental requirements. The study identified aluminium components as a major contributor to GWP100 for both LIFE chair models and also highlighted the sensitivity of the results to its recycled content. Thus, it is recommended that the use of aluminium in future product designs be limited unless it is possible to use aluminium with a high recycled content. With respect to waste management, it was found that a substantial reduction in the GWP100 impact would occur if the chairs are recycled rather than landfilled, assuming an expanding market for aluminium. Thus, recycling the two LIFE chair models at end-of-life is highly recommended.     

Life cycle assessment of construction materials: the influence of assumptions in end-of-life modelling

Purpose

The nature of end-of-life (EoL) processes is highly uncertain for constructions built today. This uncertainty is often neglected in life cycle assessments (LCAs) of construction materials. This paper tests how EoL assumptions influence LCA comparisons of two alternative roof construction elements: glue-laminated wooden beams and steel frames. The assumptions tested include the type of technology and the use of attributional or consequential modelling approaches.

Methods

The study covers impact categories often considered in the construction industry: total and non-renewable primary energy demand, water depletion, global warming, eutrophication and photo-chemical oxidant creation. The following elements of the EoL processes are tested: energy source used in demolition, fuel type used for transportation to the disposal site, means of disposal and method for handling allocation problems of the EoL modelling. Two assumptions regarding technology development are tested: no development from today’s technologies and that today’s low-impact technologies have become representative for the average future technologies. For allocating environmental impacts of the waste handling to by-products (heat or recycled material), an attributional cut-off approach is compared with a consequential substitution approach. A scenario excluding all EoL processes is also considered.

Results and discussion

In all comparable scenarios, glulam beams have clear environmental benefits compared to steel frames, except for in a scenario in which steel frames are recycled and today’s average steel production is substituted, in which impacts are similar. The choice of methodological approach (attributional, consequential or fully disregarding EoL processes) does not seem to influence the relative performance of the compared construction elements. In absolute terms, four factors are shown to be critical for the results: whether EoL phases are considered at all, whether recycling or incineration is assumed in the disposal of glulam beams, whether a consequential or attributional approach is used in modelling the disposal processes and whether today’s average technology or a low-impact technology is assumed for the substituted technology.

Conclusions

The results suggest that EoL assumptions can be highly important for LCA comparisons of construction materials, particularly in absolute terms. Therefore, we recommend that EoL uncertainties are taken into consideration in any LCA of long-lived products. For the studied product type, LCA practitioners should particularly consider EoL assumptions regarding the means of disposal, the expected technology development of disposal processes and any substituted technology and the choice between attributional and consequential approaches.     

A life cycle assessment of residential waste management and prevention

Purpose

The oft-cited waste hierarchy is considered an important rule of thumb to identify preferential waste management options and places waste prevention at the top. Nevertheless, it has been claimed that waste prevention can sometimes be less favorable than recycling because (1) recycling decreases only the primary production of materials, whereas waste prevention may reduce a combination of both primary and low-impact secondary production, and (2) waste prevention decreases the quantity of material recycled downstream and the avoided impacts associated with recycling. In response to this claim, this study evaluates the life cycle effects of waste prevention activities (WPAs) on a residential waste management system.

Methods

This life cycle assessment (LCA) contrasts the net impacts of a large residential solid waste management system (including sanitary landfilling, anaerobic digestion, composting, and recycling) with a system that incorporates five WPAs, implemented at plausible levels (preventing a total of 3.6 % of waste generation tonnage) without diminishing product service consumption. WPAs addressed in this LCA reduce the collected tonnage of addressed advertising mail, disposable plastic shopping bags, newspapers, wine and spirit packaging, and yard waste (grass).

Results and discussion

In all cases, the WPAs reduce the net midpoint and endpoint level impacts of the residential waste management system. If WPAs are incorporated, the lower impacts from waste collection, transportation, sorting, and disposal as well as from the avoided upstream production of goods, more than compensate for the diminished net benefits associated with recycling and the displaced electricity from landfill gas utilization.

Conclusions

The results substantiate the uppermost placement of waste prevention within the waste hierarchy. Moreover, further environmental benefits from waste prevention can be realized by targeting WPAs at goods that will be landfilled and at those with low recycled content.     

Steel’s recyclability: demonstrating the benefits of recycling steel to achieve a circular economy

Purpose

In a world where the population is expected to peak at around 9 billion people in the next 30 to 40 years, carefully managing our finite natural resources is becoming critical. We must abandon the outdated ‘take, make, consume and dispose’ mentality and move toward a circular economy model for optimal resource efficiency. Products must be designed for reuse and remanufacturing, which would reduce significant costs in terms of energy and natural resources.

Methods

To measure progress in achieving a circular economy, we need a life cycle approach that measures the social, economic and environmental impact of a product throughout its full life cycle—from raw material extraction to end-of-life (EoL) recycling or disposal. Life cycle thinking must become a key requirement for all manufacturing decisions, ensuring that the most appropriate material is chosen for the specific application, considering all aspects of a products’ life. The steel industry has been developing LCI data for 20 years. This is used to assess a product’s environmental performance from steel production to steel recycling at end-of-life. The steel industry has developed a methodology to show the benefits of using recycled steel to make new products. Using recycled materials also carries an embodied burden that should be considered when undertaking a full LCA.

Results and discussion

The recycling methodology is in accordance with ISO 14040/44:2006 and considers the environmental burden of using steel scrap and the benefit of scrap recycling from end-of-life products. It considers the recycling of scrap into new steel as closed material loop recycling, and thus, recycling steel scrap avoids the production of primary steel. The methodology developed shows that for every 1 kg of steel scrap that is recycled at the end of the products life, a saving of 1.5 kg CO₂-e emissions, 13.4 MJ primary energy and 1.4 kg iron ore can be achieved. This equates to 73, 64 and 90 %, respectively, when compared to 100 % primary production.

Conclusions

Incorporating this recycling methodology into a full LCA demonstrates how the steel industry is an integral part of the circular economy model which promotes zero waste; a reduction in the amount of materials used and encourages the reuse and recycling of materials.

     

Developing a systematic framework for consistent allocation in LCA

Purpose

Multifunctionality in life-cycle assessment (LCA) is solved with allocation, for which many different procedures are available. Lack of sufficient guidance and difficulties to identify the correct allocation approach cause a large number of combinations of methods to exist in scientific literature. This paper reviews allocation procedures for recycling situations, with the aim to identify a systematic approach to apply allocation.

Methods

Assumptions and definitions for the most important terms related to multifunctionality and recycling in LCA are given. The most relevant allocation procedures are identified from literature. These procedures are expressed in mathematical formulas and schemes and arranged in a systematic framework based on the underlying objectives and assumptions of the procedures.

Results and discussion

If the LCA goal asks for an attributional approach, multifunctionality can be solved by applying system expansion—i.e. including the co-functions in the functional unit—or partitioning. The cut-off approach is a form of partitioning, attributing all the impacts to the functional unit. If the LCA goal asks for a consequential approach, substitution is applied, for which three methods are identified: the end-of-life recycling method and the waste mining method, which are combined in the 50/50 method. We propose to merge these methods in a new formula: the market price-based substitution method. The inclusion of economic values and maintaining a strict separation between attributional and consequential LCA are considered to increase realism and consistency of the LCA method.

Conclusions and perspectives

We identified the most pertinent allocation procedures—for recycling as well as co-production and energy recovery—and expressed them in mathematical formulas and schemes. Based on the underlying objectives of the allocation procedures, we positioned them in a systematic and consistent framework, relating the procedures to the LCA goal definition and an attributional or consequential approach. We identified a new substitution method that replaces the three existing methods in consequential LCA. Further research should test the validity of the systematic framework and the market price-based substitution method by means of case studies.

     

Comparative LCA of treatment options for US scrap tires: material recycling and tire-derived fuel combustion

Purpose

This life cycle assessment (LCA) study compares two prevalent end-of-life (EOL) treatment methods for scrap tires: material recycling and energy recovery. The primary intended use of the study results is to inform stakeholders of the relative environmental burdens and trade-offs associated with these two EOL vehicle tire treatment methods. The study supports prioritization of the waste treatment hierarchy for this material stream in the US.

Methods

This LCA compares (1) material recycling through ambient-temperature mechanical processing and (2) energy recovery through co-incineration of both whole and preprocessed scrap tires at a cement kiln. The avoided burden recycling methodology reflects the substitution of virgin synthetic rubber used in asphalt modification with the ground tire rubber from material recycling and the substitution of conventional kiln fuels with the tire-derived fuel (TDF). Both attributional (ALCA) and consequential (CLCA) methodologies are used: the ALCA assesses the environmental profiles of the treatment methods and the CLCA examines the potential effects of shifting more scrap tires to material recycling. The attributional portion of the LCA study was conducted in accordance with ISO standards 14044 series.

Results

The results in both methodological approaches indicate that the material recycling scenario provides greater impact reductions than the energy recovery scenario in terms of the examined environmental impact potentials: energy demand, iron ore consumption, global warming potential, acidification, eutrophication, smog formation, and respiratory effects. The additional impact reductions from material recycling are significant, and the establishment of new infrastructure required for a shift to material recycling incurs relatively insignificant burdens. Sensitivity analyses indicate that this conclusion does not change for (1) a range of TDF heating values, (2) a decrease in the mixed scrap tire rubber-to-steel composition ratio, (3) two alternative electricity grid fuel mixes with higher and lower carbon dioxide emission rankings than that of the baseline scenario, or (4) a comparison of material recycling to energy recovery when TDF is used in pulp and paper mills instead of cement kilns.

Conclusions

These results provide a basis for more informed decision-making when prioritizing scrap tire waste treatment hierarchy.     

LCA and decision making: when and how to use consequential LCA; 62nd LCA forum,Swiss Federal Institute of Technology,Zürich, 9 September 2016

The 62nd life cycle assessment (LCA) forum was held on 9 September 2016 to discuss the state of research and application with regard to consequential life cycle assessment. This conference report presents the highlights of the LCA forum. The state of the art of consequential LCA was presented from different viewpoints. It was pointed out that consequential LCA is more than marginal mixes and avoided burdens and involves causal modelling. It was also said that social responsibility calls for consequential LCA. Currently, different models are used to support decision making. It was suggested to make use of the variety of models to check the conclusiveness of their results and thus the reliability of the LCAs. Current and future implementations of consequential LCI models in background databases and linking algorithms were presented. Several speakers presented consequential LCA case studies covering the sectors energy, transport, housing and mining. Some of the LCA models used in the case studies are complemented with general and partial computable equilibrium models and agent-based models and use environmentally extended input-output data or process-based LCA data. Some of the presentations focused on elements such as constrained production, marginal market mixes and technologies or recycling and system expansion. In three parallel workshops, the needs, contents and methodology, and implementation of consequential LCA approaches were discussed. The participants seemed to generally agree on the basic goal that LCA should be able to reflect the consequences of decisions. The inquiry among the participants showed that the demand for consequential LCA studies is hardly existent. The appropriate implementation of consequential modelling in LCA databases and on the appropriate model to be used in consequential LCA case studies was debated. It revealed a need for further and extensive discussions to be able to reach (minimum) consensus.     

Life-cycle assessment of domestic and transboundary recycling of post-consumer PET bottles

Background, aim, and scope  

In recent years, besides being recycled domestically, a part of Japanese post-consumer polyethylene terephthalate (PET) bottles have been exported to and recycled in mainland China. In this study, life-cycle assessment (LCA) was applied to compare domestic and transboundary recycling scenarios between Japan and China and disposal scenarios from the viewpoints of greenhouse gases (GHG) emission and fossil resource consumption.     

Lead industry life cycle studies: environmental impact and life cycle assessment of lead battery and architectural sheet production

Purpose

This paper will give an overview of LCA studies on lead metal production and use recently conducted by the International Lead Association.

Methods

The lead industry, through the International Lead Association (ILA), has recently completed three life cycle studies to assess the environmental impact of lead metal production and two of the products that make up approximately 90 % of the end uses of lead, namely lead-based batteries and architectural lead sheet.

Results and discussion

Lead is one of the most recycled materials in widespread use and has the highest end-of-life recycling rate of all commonly used metals. This is a result of the physical chemical properties of the metal and product design, which makes lead-based products easily identifiable and economic to collect and recycle. For example, the end-of-life collection and recycling rates of lead automotive and industrial batteries and lead sheet in Europe are 99 and 95 %, respectively, making them one of the few products that operate in a true closed loop. These high recycling rates, coupled with the fact that both lead-based batteries and architectural lead sheet are manufactured from recycled material, have a beneficial impact on the results of LCA studies, significantly lowering the overall environmental impact of these products. This means that environmental impacts associated with mining and smelting of lead ores are minimised and in some cases avoided completely. The lead battery LCA assesses not only the production and end of life but also the use phase of these products in vehicles. The study demonstrates that the technological capabilities of innovative advanced lead batteries used in start-stop vehicles significantly offset the environmental impact of their production. A considerable offset is realised through the savings achieved in global warming potential when lead-based batteries are installed in passenger vehicles with start-stop and micro-hybrid engine systems which have significantly lower fuel consumption than regular engines.

Conclusions

ILA has undertaken LCAs which investigate the environmental impact associated with the European production of lead metal and the most significant manufactured lead products (lead-based batteries used in vehicles and architectural lead sheet for construction) to ensure up-to-date and robust data is publically and widely available.

     

Provision of LCI data in the European aluminium industry Methods and examples

Background, aim, and scope

The development of robust and up-to-date generic life cycle inventory data for materials is absolutely crucial for the LCA community since many LCA studies rely on these generic data about materials. LCA databases and software usually include within their package such generic LCI datasets. However, in many cases, the quality of these data is poor while the methodology and the models used for their development are rarely accessible or transparent. This paper presents the development of robust European LCI datasets for the production of primary and recycled aluminium ingots and for the transformation of aluminium ingot into semi-finished products, i.e. sheet, foil and extrusion.

Materials and methods

The environmental data have been collected through an extensive environmental survey, organised among the European aluminium industry, focusing on the year 2005 and covering EU27 countries as well as EFTA countries (Norway, Iceland and Switzerland). From this survey, European averages, i.e. foreground data, have been calculated for the direct inputs and outputs of the various aluminium processes. Using the GaBi software, the foreground data have been combined within LCI models integrating background LCI data on energy supply systems, ancillary processes and materials. For the primary aluminium production (smelters), a specific model for the electricity production has been developed. The methodology for the data consolidation and for the development of the various models is explained as well as the main differences between the new modelling approach and LCI models used in the past. An independent expert has critically reviewed the entire LCI project including data collection, models development, calculation of LCI data and associated environmental indicators.

Results

As confirmed by the critical review, the new LCI datasets for aluminium ingot production and transformation into semi-finished products have been developed though a robust methodology in full accordance with ISO 14040 and 14044. Most significant environmental data and LCI results are reported in this paper with an emphasis on energy use and the major emissions to air. The full environmental report, including the critical review report and the calculation of environmental indicators for a pre-set of impact categories, is available on the website of the European Aluminium Association (EAA 2008). Whenever possible, the updated European averages and the new LCI data are compared with previous results developed from two past European surveys covering respectively the years 2002 and 1998. For the aluminium processes related to primary production, European averages are also benchmarked against global averages calculated from two worldwide surveys covering the years 2000 and 2005.

Discussion

While some data evolutions are directly attributed to the variation of foreground data, e.g. raw materials consumption or energy use within the aluminium processes, modifications related to the system boundaries, the background data and the modelling hypotheses can also influence significantly the LCI results. For primary aluminium production, the evolution of the foreground data is dominated by the strong decrease of PFC (perfluorocarbon) emissions (about 70% since 1998). In addition, the electricity structure calculated from the refined electricity model shows significant differences compared to previous models. In the 2005 electricity model, the hydropower share reaches 58% while coal contributes to 15% only of the electricity production. In 1998, the respective share of coal-based and hydro-electricity were respectively calculated to 25% and 52%. As a result, the electricity background LCI data are then significantly affected and influence also positively the environmental profile of primary aluminium in Europe. For the semi-production processes, the reduction of process scrap production, especially for extrusion and foil, demonstrates the increase of process efficiency from 1998. In parallel, a significant reduction of energy use is observed between 1998 and 2005. However, this positive trend is not fully reflected within LCI data due to the significant contribution of the background electricity data. The choice of the electricity model plays also a critical role for these transformation processes since electricity production contributes to about 2/3 of the consumption of the non-renewable energy and to about the same level of the air emissions. In such a case, the move from the UCPTE electricity model used in the past towards the EU25 electricity model used for the development of the updated LCI data has a detrimental effect on the environmental profile of the three LCI datasets respectively related to sheet, foil and extrusion. In addition to energy and process scrap reduction, the reduction of the VOC (volatile organic compounds) emission is also a major trend in foil production. Finally, for old aluminium scrap recycling, the new LCI data show a dramatic improvement regarding energy efficiency, reinforcing the environmental soundness of promoting and supporting aluminium recycling within the aluminium product life cycles.

Conclusions

This paper shows the development of generic LCI data about aluminium production and transformation processes which are based on robust data, methodologies and models in full accordance with ISO 14040 and 14044 standards, as confirmed by the critical review. The publishing of these LCI datasets definitely shows the commitment of the European aluminium industry to contribute in a transparent, fair and scientifically sound manner to product sustainability in a life cycle thinking perspective.

Recommendations and perspectives

Software houses and LCA practitioners are invited to update their generic European data on aluminium with the herewith datasets. Even if the quality and the completeness of these LCI data reach a high standard, some areas for data improvements have been identified, as described within the review report. Land use, water use and solid waste treatment appear as three priority areas for data refining and improvement. The land use dimension, particularly meaningful for bauxite mining, is not covered in the current LCI data while it is now integrated within many LCA studies. Up to now, the reporting of meaningful and robust data on water origins and use have not been possible due to the huge discrepancies between the surveyed sites combined with the difficulty to report coherent input and output water mass flows. The development of water data, only focussing on water-stressed areas, will most probably make more sense in the future. Finally, collecting more qualitative information about solid waste processing and treatment will help to include such operations within the system boundaries and to model their associated air, water and soil emissions.

     

Life cycle assessment of a waste lubricant oil management system

Purpose

This paper compares 16 waste lubricant oil (WLO) systems (15 management alternatives and a system in use in Portugal) using a life cycle assessment (LCA). The alternatives tested use various mild processing techniques and recovery options: recycling during expanded clay production, recycling and electric energy production, re-refining, energy recovery during cement production, and energy recovery during expanded clay production.

Methods

The proposed 15 alternatives and the actual present day situation were analyzed using LCA software UMBERTO 5.5, applied to eight environmental impact categories. The LCA included an expansion system to accommodate co-products.

Results

The results show that mild processing with low liquid gas fuel consumption and re-refining is the best option to manage WLO with regard to abiotic depletion, eutrophication, global warming, and human toxicity environmental impacts. A further environmental option is to treat the WLO using the same mild processing technique, but then send it to expanded clay recycling to be used as a fuel in expanded clay production, as this is the best option regarding freshwater sedimental ecotoxicity, freshwater aquatic ecotoxicity, and acidification.

Conclusions

It is recommended that there is a shift away from recycling and electric energy production. Although sensitivity analysis shows re-refining and energy recovery in expanded clay production are sensitive to unit location and substituted products emission factors, the LCA analysis as a whole shows that both options are good recovery options; re-refining is the preferable option because it is closer to the New Waste Framework Directive waste hierarchy principle.     

Environmental and energy assessment of the substitution of chemical fertilizers for industrial wastes of ethanol production in sugarcane cultivation in Brazil

Purpose

Vinasse and filter cake are residues of bioethanol processing that are used to be recycled as fertilizers in sugarcane plantation. Studies related to the environmental dimension on this practice are concerned only with the effects on water and soil. The present study examines the systemic effects of replacing chemical fertilizers with vinasse and filter cake on the environmental performance of ethanol, via life cycle assessment (LCA).

Methods

The analysis was carried out by comparing various scenarios structured from two control variables: crop management techniques (manual and mechanized harvesting) and source of nutrients (for supplying the nutritional needs of sugarcane crops): chemical fertilizers, chemical fertilizers + vinasse, and chemical fertilizer + vinasse + filter cake. Impact assessment was carried out in terms of primary energy demand, climate change, terrestrial acidification, freshwater eutrophication, human toxicity, and terrestrial ecotoxicity. LCA has been applied according to both attributional and consequential perspectives. Moreover, a sensitivity analysis was performed in order to verify the effects of the varying amounts of nitrogen (N), phosphorus (P), and potassium (K) in the composition of vinasse on the results obtained for the impact profile.

Results and discussion

From the attributional LCA perspective, the most expressive contributions regarding primary energy demand occurred in terms of depletion of non-renewable fossils. Replacing chemical fertilizers with vinasse and filter cake was beneficial for the environmental performance of ethanol as it reduces climate change, terrestrial acidification, and human toxicity impacts and sustains freshwater eutrophication and terrestrial ecotoxicity unaltered in relation to scenarios using only fertilizers. In terms of consequential LCA, ethanol’s environmental performance is influenced by the inclusion of the production of calcium fluorite to compensate the hexafluorosilicic acid deficit occurring in conjunction to the decrease of phosphate fertilizer and is compensated by the benefits provided by the general reduced consumption of chemical fertilizers for most of the impact categories. The exception occurred for primary energy demand.

Conclusions

The reuse of residues from bioethanol production—vinasse and filter cake—as primary nutrient suppliers for the cultivation of sugarcane instead of chemical fertilizers is a valid practice that improves the environmental performance of ethanol, even if it is analyzed under a consequential LCA perspective. The transport of these inputs to the field must be managed, however, in order to minimize primary energy demand and climate change impacts.

     

LCA of soybean meal

Background, Aim and Scope  Soybean meal is an important protein input to the European livestock production, with Argentina being an important supplier. The area cultivated with soybeans is still increasing globally, and so are the number of LCAs where the production of soybean meal forms part of the product chain. In recent years there has been increasing focus on how soybean production affects the environment. The purpose of the study was to estimate the environmental consequences of soybean meal consumption using a consequential LCA approach. The functional unit is ‘one kg of soybean meal produced in Argentina and delivered to Rotterdam Harbor’. Materials and Methods  Soybean meal has the co-product soybean oil. In this study, the consequential LCA method was applied, and co-product allocation was thereby avoided through system expansion. In this context, system expansion implies that the inputs and outputs are entirely ascribed to soybean meal, and the product system is subsequently expanded to include the avoided production of palm oil. Presently, the marginal vegetable oil on the world market is palm oil but, to be prepared for fluctuations in market demands, an alternative product system with rapeseed oil as the marginal vegetable oil has been established. EDIP97 (updated version 2.3) was used for LCIA and the following impact categories were included: Global warming, eutrophication, acidification, ozone depletion and photochemical smog. Results  Two soybean loops were established to demonstrate how an increased demand for soybean meal affects the palm oil and rapeseed oil production, respectively. The characterized results from LCA on soybean meal (with palm oil as marginal oil) were 721 gCO₂ eq. for global warming potential, 0.3 mg CFC11 eq. for ozone depletion potential, 3.1 g SO₂ eq. for acidification potential, −2 g NO₃ eq. for eutrophication potential and 0.4 g ethene eq. for photochemical smog potential per kg soybean meal. The average area per kg soybean meal consumed was 3.6 m²year. Attributional results, calculated by economic and mass allocation, are also presented. Normalised results show that the most dominating impact categories were: global warming, eutrophication and acidification. The ‘hot spot’ in relation to global warming, was ‘soybean cultivation’, dominated by N₂O emissions from degradation of crop residues (e.g., straw) and during biological nitrogen fixation. In relation to eutrophication and acidification, the transport of soybeans by truck is important, and sensitivity analyses showed that the acidification potential is very sensitive to the increased transport distance by truck. Discussion  The potential environmental impacts (except photochemical smog) were lower when using rapeseed oil as the marginal vegetable oil, because the avoided production of rapeseed contributes more negatively compared with the avoided production of palm oil. Identification of the marginal vegetable oil (palm oil or rapeseed oil) turned out to be important for the result, and this shows how crucial it is in consequential LCA to identify the right marginal product system (e.g., marginal vegetable oil). Conclusions  Consequential LCAs were successfully performed on soybean meal and LCA data on soybean meal are now available for consequential (or attributional) LCAs on livestock products. The study clearly shows that consequential LCAs are quite easy to handle, even though it has been necessary to include production of palm oil, rapeseed and spring barley, as these production systems are affected by the soybean oil co-product. Recommendations and Perspectives  We would appreciate it if the International Journal of Life Cycle Assessment had articles on the developments on, for example, marginal protein, marginal vegetable oil, marginal electricity (related to relevant markets), marginal heat, marginal cereals and, likewise, on metals and other basic commodities. This will not only facilitate the work with consequential LCAs, but will also increase the quality of LCAs.     

Experiences with the critical review process of aluminium LCI data

Background, aim, and scope

This paper summarises the critical review process according to ISO 14040/44 performed for the European Aluminium Association (EAA), Brussels. Scope of the review was a life cycle inventory (LCI) project, aiming at providing the life cycle assessment (LCA) community with reliable generic data relevant for the European aluminium market, including the production of aluminium ingot either from primary aluminium or from recycled aluminium and the fabrication of semi-finished products, i.e. sheet, foil or extrusion fabrication from aluminium ingots.

Main features

Critical reviewing according to ISO 14040 and 14044, although described formally in the standards, evolved essentially via ‘learning by doing’. This special review has been conducted as a critical review by one external expert. Since no comparative assertions are to be expected from the results obtained, a critical review according to the panel method (at least three reviewers) was deemed not to be necessary. The review process was interactive and took about a year (March 2007 to April 2008). The full review report is printed in full length at the end of the published LCI data report.

Results

The report continues the tradition of the former reports but offers new aspects. The main change refers to the use of new software for data handling (GaBi 4.0 replacing the formerly used LCA-2 based on BUWAL data), including generic data for ancillary processes and inputs for the energy model. The LCI results, therefore, cannot be compared exactly with the data of the previous reports. There is no disconnection, however, so that trends can be observed and discussed with some precaution. The main trend with respect to energy and emissions is one of slow but steady improvement. A main methodological improvement with regard to the former projects is the new energy model, especially with regard to imported primary aluminium.

Discussion

There was some discussion about the term ‘waste’ when it is put outside the system boundary together with the resulting emissions. According to the author’s opinion, there are at least three types of waste: (1) waste to be reused or recycled—this waste stays within the technosphere and, thus, within the system boundaries of a typical LCA; (2) waste to be collected and removed legally by incineration, controlled landfilling or composting—this waste stays within the technosphere, too; only the emissions of the waste removal processes (CO₂, CH₄, organic contaminants to ground water, leached metal ions to ground water, etc.) escape into the environment if not collected properly; (3) waste thrown away, e.g. by littering, illegal dumping, burning, etc.; this waste ends up in the environment if not collected. There was a time when solid waste in LCA (if landfilled) was considered as an ‘emission into soil’. This is only true for illegal, uncontrolled land filling. Controlled landfilling is a kind of process and belongs to the technosphere as long as it is controlled. EAA envisages to include appropriate data in future updates (incineration is already included).

Conclusions

According to ISO 14040, “The critical review process shall ensure that: the methods used to carry out the LCA are consistent with the international Standard; the methods used to carry out the LCA are scientifically and technically valid, the data used are appropriate and reasonable in relation to the goal of the study; the interpretations reflect the limitations identified and the goal of the study; the study report is transparent and consistent.” These five points can be confirmed with a few restrictions. With regard to the first item, consistency with ISO 14040/44, there is a formal lack of a section ‘interpretation’. It was also discussed that the study is not a full LCA, but the standard allows for LCI studies. As such, the study conforms to ISO. The methods used in data collection and modelling are described clearly and correspond to the state of the art. They should be published and become standard for generic data collection.

Perspectives

It is assumed and recommended that the process of continuous improvement (both technological and relating to data collection and modelling) will continue in the following years. However, since raw aluminium production is faced with thermodynamic limits, it is proposed to rethink the whole aluminium system, which is based on a century-old technology and to conceive bold new routes, especially aiming at a further increase of renewable energy use and further improving recycling in countries with deficient waste collecting systems. The use of heavy fuel oil in alumina production should be discouraged.

     

Life cycle assessment of Australian automotive door skins

Background, aim, and scope  Policy initiatives, such as the EU End of Life Vehicle (ELV) Directive for only 5% landfilling by 2015, are increasing the pressure for higher material recyclability rates. This is stimulating research into material alternatives and end-of-life strategies for automotive components. This study presents a Life Cycle Assessment (LCA) on an Australian automotive component, namely an exterior door skin. The functional unit for this study is one door skin set (4 exterior skins). The material alternatives are steel, which is currently used by Australian manufacturers, aluminium and glass-fiber reinforced polypropylene composite. Only the inputs and outputs relative to the door skin production, use and end-of-life phases were considered within the system boundary. Landfill, energy recovery and mechanical recycling were the end-of-life phases considered. The aim of the study is to highlight the most environmentally attractive material and end-of-life option. Methods  The LCA was performed according to the ISO 14040 standard series. All information considered in this study (use of fossil and non fossil based energy resources, water, chemicals etc.) were taken up in in-depth data. The data for the production, use and end-of-life phases of the door skin set was based upon softwares such as SimaPro and GEMIS which helped in the development of the inventory for the different end-of-life scenarios. In other cases, the inventory was developed using derivations obtained from published journals. Some data was obtained from GM-Holden and the Co-operative research Centre for Advanced Automotive Technology (AutoCRC), in Australia. In cases where data from the Australian economy was unavailable, such as the data relating to energy recovery methods, a generic data set based on European recycling companies was employed. The characterization factors used for normalization of data were taken from (Saling et. al. Int J Life Cycle Assess 7(4):203–218 2002) which detailed the method of carrying out an LCA. Results  The production phase results in maximum raw material consumption for all materials, and it is higher for metals than for the composite. Energy consumption is greatest in the use phase, with maximum consumption for steel. Aluminium consumes most energy in the production phase. Global Warming Potential (GWP) also follows a trend similar to that of energy consumption. Photo Oxidants Creation Potential (POCP) is the highest for the landfill scenario for the composite, followed by steel and aluminium. Acidification Potential (AP) is the highest for all the end-of-life scenarios of the composite. Ozone Depletion Potential (ODP) is the highest for the metals. The net water emissions are also higher for composite in comparison to metals despite high pollution in the production phases of metallic door skins. Solid wastes are higher for the metallic door skins. Discussion  The composite door skin has the lowest energy consumption in the production phase, due to the low energy requirements during the manufacturing of E-glass and its fusion with polypropylene to form sheet molding compounds. In general, the air emissions during the use phase are strongly dependent on the mass of the skins, with higher emissions for the metals than for the composite. Material recovery through recycling is the highest in metals due to efficient separation techniques, while mechanical recycling is the most efficient for the composite. The heavy steel skins produce the maximum solid wastes primarily due to higher fuel consumption. Water pollution reduction benefit is highest in case of metals, again due to the high efficiency of magnetic separation technique in the case of steel and eddy current separation technique in the case of aluminium. Material recovery in these metals reduces the amount of water needed to produce a new door skin set (water employed mainly in the ingot casting stage). Moreover, the use of heavy metals, inorganic salts and other chemicals is minimized by efficient material recovery. Conclusions  The use of the studied type of steel for the door skins is a poor environmental option in every impact category. Aluminium and composite materials should be considered to develop a more sustainable and energy efficient automobile. In particular, this LCA study shows that glass-fiber composite skins with mechanical recycling or energy recovery method could be environmentally desirable, compared to aluminium and steel skins. However, the current limit on the efficiency of recycling is the prime barrier to increasing the sustainability of composite skins. Recommendations and perspectives  The study is successful in developing a detailed LCA for the three different types of door skin materials and their respective recycling or end-of-life scenarios. The results obtained could be used for future work on an eco-efficiency portfolio for the entire car. However, there is a need for a detailed assessment of toxicity and risk potentials arising from each of the four different types of door skin sets. This will require greater communication between academia and the automotive industry to improve the quality of the LCA data. Sensitivity analysis needs to be performed such as the assessment of the impact of varying substitution factors on the life cycle of a door skin. Incorporation of door skin sets made of new biomaterials need to be accounted for as another functional unit in future LCA studies. Discussion contributions to this article from the readership would the highly welcome. The authors     

Recycling of aluminum can in terms of Life Cycle Inventory (LCI)

Background, Aims and Scope  Life Cycle Assessment is a technique for evaluating the environmental performance of a given product by: identifying and quantifying the energy and raw materials used in its manufacturing process, as well as the emissions of pollutants to water, soil, and air inherent in this production, use and disposal, and evaluating the environmental impact associated with the use of energy and materials and the emissions of pollutants, thus identifying opportunities to improve the system in order to optimize the environmental performance of the product. CETEA (Packaging Technology Center) has conducted a Life Cycle Assessment — LCA study of aluminum can with emphasis in life cycle inventory, collecting data for the reference years 2000–2002. The goal of this paper is to present part of this complete study, focusing the influence of aluminium recycling rate on the Life Cycle Inventory (LCI) of aluminum beverage cans in Brazil. Methods  The adopted methodology was based on the recommendations of SETAC — Society of Environmental Toxicology and Chemistry and the ISO 14040 Standard, approved by the Sub-Committee 05 of the Environmental Administration Technical Committee, TC-207, from ISO — INTERNATIONAL ORGANIZATION FOR STANDARDIZATION [1,2]. Data storage and modeling were performed by employing the PIRA Environmental Management System — PEMS [3]. Results  Taking into account the impact categories adopted in this study, it has been shown that recycling helps to improve the aluminium can environmental profile measured as LCI data. Discussion  For the transformed aluminium products, the recycling rate affects the values of the environmental parameters inventoried, but not in the same proportion, since the contribution of other stages of the product system life cycle and the recycling process remain unchanged, including the yield of this process. In general, the recycling balance is always positive due to the importance of the stages that precede the packaging production and the problem of increasing the municipal waste volume. Conclusions  The advantages of the recycling are obviously concentrated on the inventoried parameters related to the primary aluminum production and to the package disposal. The verified benefits of the recycling increase with the recycling rate enhancement. However, the effects on the inventory do not have the same magnitude of the recycling rate. This happens due to the relative contributions of the other life cycle stages, such as the transportation and sheet or can production. In agreement with the presented results, it is possible to conclude that the aluminum can recycling reduces part of the consumption of natural resources and the emissions associated to the stages previous to the production of the packaging. The parameters specifically related to the stage of aluminum production suffer reduction directly proportional to the increase of the recycling rate. In this way, all of the efforts made to increase the recycling rate will have a positive contribution to the LCI of the aluminum can. Recommendations  It is worth pointing out that LCA studies are iterative and dynamic. The data can always be refined, substituted or complemented with updated information in order to improve the representativeness of the analyzed sector. Perspectives  From this study, the aluminum sector in Brazil is able to quantify the benefits of future actions for environmental improvement of the Brazilian aluminum industry, as well as to contribute technically to Environmental Labeling initiatives regarding aluminum products. ESS-Submission Editor: Alain Dubreuil (dubreuil@nrcan.gc.ca)     

Life cycle assessment of sponge nickel produced by gas atomisation for use in industrial hydrogenation catalysis applications

Purpose

This paper presents a cradle-to-grave comparative life cycle assessment (LCA) of new gas atomised (GA) sponge nickel catalysts and evaluates their performance against the current cast and crush standard currently used in the industrial hydrogenation of butyraldehyde to butanol.

Methods

A comparative LCA has been made, accounting for the energy used and emissions throughout the entire life cycle of sponge nickel catalysts—ranging from the upstream production of materials (mainly aluminium and nickel), to the manufacturing, to the operation and finally to the recycling and disposal. The LCA was performed following ISO14040 principles where possible, and subsequently implemented in the software package GaBi 4.3. The CML2001 impact assessment methodology was used, with primary focus on comparing catalysts for equivalent greenhouse gasses generated over their lifetime and their relative global warming potential and secondary focus on acidification potential. This is justified as the lifetime is dominated by energy use in the operational phase, and acidification is dominated by the production of nickel for which existing ISO14040 collected data has been used. A sensitivity analysis was used to provide a number of scenarios and overall environmental performances of the various sponge nickels considered when compared to the existing industrial standard.

Results and discussion

It was found that the energy and emissions during the operation phase associated with a given catalyst significantly outweigh the primary production, manufacturing and recycling. Primary production of the nickel (and to a lesser extent molybdenum when used as a dopant) also has a significant environmental impact in terms of acidification potential, but this is offset by operational energy savings over the catalysts’ estimated lifetime and end of life recyclability. Finally, the impact of activity improvement and lifetime duration of sponge nickel catalysts was determined as both total life cycle energy for operational use and as a total life cycle global warming potential.

Conclusions

From this assessment, the newly developed, higher activity spongy nickel catalysts produced by gas atomisation could have a significantly lower environmental impact than the current industry standard cast and crush method. Given the potential environmental benefits of such catalysts, applications in other processes that require a catalyst should also be investigated.