Life cycle assessment of fine chemical production: a case study of pharmaceutical synthesis

Background, aim, and scope  

Pharmaceuticals have been recently discussed in the press and literature regarding their occurrence in rivers and lakes, mostly due to emissions after use. The production of active pharmaceutical ingredients (APIs) has been less analyzed for environmental impacts. In this work, a life cycle assessment (LCA) of the production of an API from cradle to factory gate was carried out. The main sources of environmental impacts were identified. The resulting environmental profile was compared to a second pharmaceutical production and to the production of basic chemicals.     

Life cycle assessment in urban territories: a case study of Dalian city,China

The International Journal of Life Cycle Assessment - A city comprises different subsystems, such as an industry subsystem, agriculture subsystem, building subsystem, and transport subsystem. With...     

Life cycle assessment of bio-based products: a disposable diaper case study

Purpose

In this study, a life cycle assessment of a bioplastic based diaper was performed. The product has several innovative elements, due to the implementation of eco-design principles, such as: (1) introduction of biopolymers (namely polylactic acid (PLA) and Mater-bi®), (2) relevant reduction of petrochemical plastics, and (3) minimization of energy consumptions and use of renewable energy in manufacturing. The aim of the study is to evaluate the environmental benefits gained through eco-innovation, while identifying further areas of improvement.

Methods

The bio-based diaper has been evaluated using a “cradle-to-gate” analysis. The functional unit is one diaper, assuming an average size among the different commercial options. A case study of an enterprise in Italy (WIP S.p.A) was carried out to collect as much reliable primary data as possible. In order to highlight potential areas of improvement and to compare the environmental performance of the product, a sensitivity analysis based on three different impact assessment methods (adopting ReCiPe 2008, IMPACT 2002+ and Cumulative Energy Demand (CED)) and a comparison with a standard commercial diaper were performed. Finally, three possible end-of-life scenarios including composting of WIP diaper were hypothesized and tested.

Results and discussion

Contribution analysis suggested that sourcing and production of raw materials used in WIP diaper manufacturing contributed most significantly to the potential environmental impacts. Adopting ReCiPe method, pulp, and sodium polyacrylate present the highest environmental burdens in WIP diaper system. Applying IMPACT2002+ method, PLA relative contribution to the toxicity increases, due to the generation of the electricity used in corn production and in PLA production phases. For both methods, impacts related to energy consumption of the WIP diapers’ production process look to be negligible. WIP diaper performance has room for improvement, since critical points were detected in the life cycle stages of raw materials used. However, the results of the normalization step, according to ReCiPe method, state that WIP diapers can bring environmental benefits, compared to standard ones. Moreover, if composting end-of-life scenario is included in the assessment, there is a significant improvement in WIP diaper environmental performance compared to a standard diaper.

Conclusions

Integrating eco-innovation and eco-design principles in the production of the bio-based diaper leads to a better environmental profile, compared to the standard one. Nevertheless, there are several areas of concerns to be considered in order to further improve its environmental performance. So far, the possible improvements identified from the case study are: (1) the selection of biopolymers suppliers with better production systems from an environmental point of view, (2) the reduction of distances along the supply chain, and (3) the implementation of composting procedures for the end of life. In conclusion, the introduction of biopolymers in diaper composition could lead them to be preferable compared to standard diapers, but criticisms arise, which need to be solved, to avoid the risk of burdens shifting.     

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 bacterial cellulose production

The International Journal of Life Cycle Assessment - Bacterial cellulose (BC), obtained by fermentation, is an innovative and promising material with a broad spectrum of potential applications....     

Life cycle assessment of construction and demolition waste management systems: a Spanish case study

Purpose  

The aim of this study is to develop and analyse a life cycle inventory of construction and demolition waste (C&DW) management systems based on primary data collected directly from Spanish enterprises involved in the life cycle of this type of waste material. Special emphasis is placed on assessing the environmental profile of inert waste sorting and treatment (IWST) facilities.     

Life cycle assessment for emerging materials: case study of a garden bed constructed from lumber produced with three different copper treatments

Purpose

The objective of this research was to evaluate the appropriateness of using life cycle assessment (LCA) for new applications that incorporate emerging materials and involve site-specific scenarios. Cradle-to-grave impacts of copper-treated lumber used in a raised garden bed are assessed to identify key methodological challenges and recommendations applying LCA for such purposes as well as to improve sustainability within this application.

Methods

The functional unit is a raised garden bed measuring 6.67 board feet (bf) in volume over a period of 20 years. The garden beds are made from softwood lumber such as southern yellow pine. The two treatment options considered were alkaline copper quaternary and micronized copper quaternary. Ecoinvent 2.2 provided certain life cycle inventory (LCI) data needed for the production of each garden bed, while additional primary and secondary sources were accessed to supplement the LCI.

Results and discussion

Primary data were not available for all relevant inventory requirements, as was anticipated, but enough secondary data were gathered to conduct a screening-level LCA on these raised garden bed applications. A notable finding was that elimination of organic solvent could result in a more sustainable lumber treatment product. Conclusions are limited by data availability and key methodological challenges facing LCA and emerging materials.

Conclusions

Although important data and methodological challenges facing LCA and emerging materials exist, this LCA captured material and process changes that were important drivers of environmental impacts. LCA methods need to be amended to reflect the properties of emerging materials that determine their fate, transport, and impacts to the environment and health. It is not necessary that all recommendations come to light before LCA is applied in the context of emerging materials. Applications of such materials involve many inputs beyond emerging materials that are already properly assessed by LCA. Therefore, LCA should be used in its current state to enhance the decision-making context for the sustainable development of these applications.     

Life cycle assessment of primary magnesium production using the Pidgeon process in China

Background, aims, and scope  China has been the largest primary magnesium producer in the world since year 2000 and is an important part of the global magnesium supply chain. Almost all of the primary magnesium in China is produced using the Pidgeon process invented in the 1940s in Canada. The environmental problems of the primary magnesium production with the Pidgeon process have already attracted much attention of the local government and enterprises. The main purposes of this research are to investigate the environmental impacts of magnesium production and to determine the accumulative environmental performances of three different scenarios. System boundary included the cradle-to-gate life cycle of magnesium production, including dolomite ore extraction, ferrosilicon production, the Pidgeon process, transportation of materials, and emissions from thermal power plant. The life cycle assessment (LCA) case study was performed on three different fuel use scenarios from coal as the overall fuel to two kinds of gaseous fuels, the producer gas and coke oven gas. The burden use of gaseous fuels was also considered. Methods  The procedures, details, and results obtained are based on the application of the existing international standards of LCA, i.e., the ISO 14040. Depletion of abiotic resources, global warming, acidification, and human toxicity were adopted as the midpoint impact categories developed by the problem-oriented approach of CML to estimate the characterized results of the case study. The local characterization and normalization factors of abiotic resources were used to calculate abiotic depletion potential (ADP). The analytic hierarchy process was used to determine the weight factors. Using the Umberto version 4.0, the emissions of dolomite ore extraction were estimated and the transportation models of the three scenarios were designed. Results and conclusions  The emissions inventory showed that both the Pidgeon process of magnesium production and the Fe–Si production were mainly to blame for the total pollutant emissions in the life cycle of magnesium production. The characterized results indicated that ADP, acidification potential, and human toxicity potential decreased cumulatively from scenarios 1 to 3, with the exception of global warming potential. The final single scores indicated that the accumulative environmental performance of scenario 3 was the best compared with scenarios 1 and 2. The impact of abiotic resources depletion deserves more attention although the types and the amount of mineral resources for Mg production are abundant in China. This study suggested that producer gas was an alternative fuel for magnesium production rather than the coal burned directly in areas where the cost of oven gas-produced coke is high. The utilization of “clean” energy and the reduction of greenhouse gases and acidic gases emission were the main goals of the technological improvements and cleaner production of the magnesium industry in China. Recommendation and perspective  This paper has demonstrated that the theory and method of LCA are actually helpful for the research on the accumulative environmental performance of primary magnesium production. Further studies with “cradle-to-cradle” scheme are recommended. Furthermore, other energy sources used in magnesium production and the cost of energy production could be treated in further research.     

Life cycle assessment of Portland cement production in Myanmar

The International Journal of Life Cycle Assessment - Cement manufacturing is associated with global and local environmental issues. Many studies have employed life cycle assessment (LCA) to...     

Life cycle assessment in the furniture industry: the case study of an office cabinet

Purpose

In an effort to reduce the environmental impacts of the furniture sector, this study aimed to diagnose the environmental performance of an office cabinet throughout its life cycle.

Methods

An attributional life cycle assessment (LCA) was used, based on the ISO 14044 Standard and ILCD Handbook. The scope of the study considered the entire supply chain, from cradle to grave, including the steps of pre-manufacturing, manufacturing, use, and post-use of the product. The impact assessment method was the International Reference Life Cycle Data System (ILCD) 2011 midpoint.

Results and discussion

The results identified that the most significant environmental impact of the furniture life cycle was due to the distances covered and production of the main raw material, wood medium-density particleboard (MDP). The evaluation of transport scenarios showed environmental tradeoffs for truck fuel switches and environmental gains for the distribution of MDP from closer suppliers by truck, as well as from current supplier by truck and ship in the major categories. Furthermore, evaluation of the office cabinet post-use options showed that reuse, recycling, or energy recovery from waste cause significant environmental gains in the major categories. Wooden furniture is a potential carbon sink if its life cycle does not emit more greenhouse gases than its materials can store. The impacts of substitution scenarios varied depending on the type of product avoided.

Conclusions

The LCA proved a powerful method to diagnose and manage environmental impacts in complex product systems. The sensitivity analysis showed that it is possible to reduce the environmental impacts and, at the same time, make the furniture industry increase its economic gains and net carbon stock in the anthroposphere.

     

Life cycle assessment of recirculating aquaculture systems: A case of Atlantic salmon farming in China

Recirculating aquaculture systems (RAS) are an alternative technology to tackle the major environmental challenges associated with conventional cage culture systems. In order to systematically assess the environmental performance of RAS farming, it is important to take the whole life cycle into account so as to avoid ad hoc and suboptimal environmental measures. So far, the application of life cycle assessment (LCA) in aquaculture, especially to indoor RAS, is still in progress. This study reports on an LCA of Atlantic salmon harvested at an indoor RAS farm in northern China. Results showed that 1 tonne live‐weight salmon production required 7,509 kWh farm‐level electricity and generated 16.7 tonnes of CO₂ equivalent (eq), 106 kg of SO₂ eq, 2.4 kg of P eq, and 108 kg of N eq (cradle‐to‐farm gate). In particular, farm‐level electricity use and feed product were identified as primary contributors to eight of nine impact categories assessed (54–95% in total), except the potential marine eutrophication (MEU) impact (dominated by the grow‐out effluents). Among feed ingredients (on a dry‐weight basis), chicken meal (5%) and krill meal (8%) dominated six and three, respectively, of the nine impact categories. Suggested environmental improvement measures for this indoor RAS farm included optimization of stocking density, feeding management, grow‐out effluent treatment, substitution of feed ingredients, and selection of electricity generation sources. In a generic context, this study can contribute to a better understanding of the life cycle environmental impacts of land‐based salmon RAS operations, as well as science‐based communication among stakeholders on more eco‐friendly farmed salmon.     

Life cycle assessment of pharmaceuticals: the ciprofloxacin hydrochloride case

The International Journal of Life Cycle Assessment - Despite the benefits in human health from pharmaceuticals, their production has simultaneously given rise to severe environmental pollution....     

Subcategory assessment method for social life cycle assessment: a case study of high-density polyethylene production in Alberta,Canada

Purpose

The aim of this study is to develop and test the applicability of a new subcategory assessment method (SAM) for social life cycle assessment using a case study on high-density polyethylene (HDPE) production by Dow Chemical Canada facility in Alberta, Canada.

Methods

The methodology is characterized by six steps: (1) definition of the goal and scope of the assessment; (2) life cycle inventory data collection including context data at country level and company-specific data for foreground processes; (3) impact assessment where the subcategories’ results for foreground processes at company level are evaluated using a new SAM developed and the country social performance in the different subcategories is evaluated using some assessment intervals; (4) comparing the social performance of foreground processes to the social background context in sector or country; (5) evaluating the social performance of background processes using sector performance evaluation from Product Social Impact Life Cycle Assessment (PSILCA) database or country performance evaluation conducted in the study; (6) and discussion and conclusion.

Results and discussion

The method developed was able to identify the subcategories that need high level or some level of improvements along the cradle-to-gate life cycle of HDPE. In addition, the stakeholders with high negative effect were highlighted in every life cycle stage. Through this approach, Dow Chemical Canada is able to prioritize its actions and focus on the areas where its performance is still low compared to its peers in the sector or compared to the situation in the country. Moreover, through using PSILCA database or country performance evaluation to investigate the social performance of background processes, Dow Chemical Canada can determine the social hotspots areas that need more focus from its suppliers.

Conclusions

Applying the new subcategory assessment approach proposed in this study provides an objective way to assess the subcategories while differentiating between two levels of assessment: (1) the commitment to the social subcategory in the company’s policy (defined as cutoff requirement) and (2) the evidence of good/bad practices of the subcategory. In addition, the comparison of performance of the companies in foreground processes to the social background in sector or country has improved the objectivity further.

     

Life cycle assessment of biodiesel production from microalgae in ponds

This paper analyses the potential environmental impacts and economic viability of producing biodiesel from microalgae grown in ponds. A comparative Life Cycle Assessment (LCA) study of a notional production system designed for Australian conditions was conducted to compare biodiesel production from algae (with three different scenarios for carbon dioxide supplementation and two different production rates) with canola and ULS (ultra-low sulfur) diesel. Comparisons of GHG (greenhouse gas) emissions (g CO₂-e/t km) and costs (¢/t km) are given. Algae GHG emissions (−27.6 to 18.2) compare very favourably with canola (35.9) and ULS diesel (81.2). Costs are not so favourable, with algae ranging from 2.2 to 4.8, compared with canola (4.2) and ULS diesel (3.8). This highlights the need for a high production rate to make algal biodiesel economically attractive.     

Life cycle assessment of chitosan production in India and Europe

Purpose

The aim of this article is to present the first life cycle assessment of chitosan production based on data from two real producers located in India and Europe. The goal of the life cycle assessment (LCA) was to understand the main hot spots in the two supply chains, which are substantially different in terms of raw materials and production locations.

Methods

The LCA is based on consequential modelling principles, whereby allocation is avoided by means of substitution, and market mixes include only flexible, i.e. non-constrained suppliers. The product system is cradle to gate and includes the production of raw materials, namely waste shells from snow crab and shrimp in Canada and India, respectively, the processing of these in China and India and the manufacture of chitosan in Europe and India. Primary data for chitin and chitosan production were obtained from the actual producers, whereas raw material acquisition as well as waste management activities were based on literature sources. The effects of indirect land use change (iLUC) were also included. Impact assessment was carried out at midpoint level by means of the recommended methods in the International Life Cycle Data (ILCD) handbook.

Results and discussion

In the Indian supply chain, the production of chemicals (HCl and NaOH) appears as an important hot spot. The use of shrimp shells as raw material affects the market for animal feed, resulting in a credit in many impact indicators, especially in water use. The use of protein waste as fertilizer is also an important source of greenhouse-gas and ammonia emissions. In the European supply chain, energy use is the key driver for environmental impacts, namely heat production based on coal in China and electricity production in China and Europe. The use of crab shells as raw material avoids the composting process they would be otherwise subject to, leading to a saving in composting emissions, especially ammonia. In the Indian supply chain, the effect of iLUC is relevant, whereas in the European one, it is negligible.

Conclusions

Even though we assessed two products from the same family, the results show that they have very different environmental profiles, reflecting their substantially different supply chains in terms of raw material (shrimp shells vs. crab shells), production locations (locally produced vs. a global supply chain involving three continents) and the different applications (general-purpose chitosan vs. chitosan for the medical sector).

     

Life cycle assessment of biomass production in microalgae compact photobioreactors

This paper presents a life cycle assessment (LCA) of industrial scale microalgae biomass production in compact photobioreactor (PBR) systems (2 × 5 × 8 m) for supplying biofuel/electricity generation processes and synthesis of new materials. Other objectives are as follows: (i) to compare the impact of various raw materials, substances, and services; and (ii) to evaluate environment‐relevant aspects of the proposed system as compared to microalgae raceway ponds. The life cycle inventory assessment shows that (i) only atmospheric CO₂ is used for PBR microalgae cultivation, whereas in raceway ponds, injection of CO₂ from fossil origin is largely required to allow for microalgae growth; and (ii) the PBR daily production rate of dry biomass is currently at 1.5 kg m^?3 day^?1 for each PBR, which is 12.82 times larger than the reported average 0.117 kg m^?3 day^?1 raceway ponds production. It is found that in general the association of the effects of the production of steel, PVC, and the packaging contribute to more than 85% of the total impact in each analyzed category. Therefore, to achieve PBR biomass production impact reduction and sustainability, PVC and steel utilization need to be minimized, as well as packaging materials. Based on the PBR LCA results, that is, due to no CO₂ injection from fossil origin and low area occupation, it is expected that high density production of truly renewable microalgae biomass could be obtained from PBR systems.     

Life cycle assessment applying planetary and regional boundaries to the process level: a model case study

The International Journal of Life Cycle Assessment - The planetary boundaries framework contains regional boundaries in addition to global boundaries. Geographically resolved methods to assess...     

Life cycle assessment as a tool for improving process performance: A case study on boron products

This paper explores the use of LCA as a tool for process environmental management, thereby moving the focus from product to process oriented analysis. The emphasis is on Improvement Assessment in which the “hot spots” in the system are targeted for maximum environmental improvements. In this context, it is useful to use multiobjective optimisation which renders Valuation unnecessary. The approach is illustrated by the case study of the system processing boron ores to make five different products. The results of Inventory Analysis and Impact Assessment are presented and discussed. In Improvement Assessment, a number of improvement options are identified and evaluated, using system optimisation. It is shown that the site environmental performance can be improved over current operation by an average of 20% over the whole life cycle. Thus the study demonstrates that the optimisation approach to environmental process management may assist in identifying optimal ways to operate a process or plant from “cradle to grave”. This may help the process industries not only to comply with legislation but also provide a framework for taking a more proactive approach to environmental management leading to more sustainable industrial operations and practices.