Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
Sutardja Dai Hall, Berkeley
23/05/2012
CO2PE! - UPLCI Workshop
23/05/12
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
1. Welcome and Introduction
Prof. Michael Overcash
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Overview
Welcome and Introduction
CO2PE! – UPLCI Methodology
DIN 8580 – Process Taxonomy
Experiences with screening UPLCI
Hands-on session
Integration within LCI-databases
Future action items and Discussion
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Manufacturing Sector Background

Tens to hundreds of thousands of manufacturing plants (known as
transformational steps because these convert materials and chemicals into
macro-shape products)

Output of families of products (simple to complex)

Stakeholder expectations

Company has invested in a life cycle understanding of their products

Can provide some form of quantitative environmental footprint of their
products

The unit process life cycle inventory (UPLCI) concept has been developed to
meet these large global needs of manufacturers and stakeholders

UPLCI is a building block concept to estimate energy and material use at the
machine level of a manufacturing plant

For most manufacturing facilities transforming materials or chemicals into
industrial or consumer products there are about 120 separate unit processes
that are used
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
2. CO2PE!-UPLCI Methodology
Prof. Joost Duflou
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Methodology for Systematic Analysis and Improvement
of Manufacturing Unit Process Life Cycle Inventory
Machine Tool Level
Life Cycle Inventory data
Sub-Process Level
Optimisation Measures
& Eco-Design Guidelines
Kellens, K., Dewulf, W., Overcash, M., Hauschild, M., Duflou, J.R. (2012), Methodology
for systematic analysis and improvement of manufacturing unit process life cycle
inventory (UPLCI), Int. Journal of Life Cycle Assessment, Vol. 17/1:69-78.
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Methodology for Systematic Analysis and Improvement
of Manufacturing Unit Process Life Cycle Inventory
Functional Unit:
Quantifies the qualitative and quantitative aspects
of the (main) function(s) of the manufacturing unit
process along the questions “what”, “how much”,
“how well”, and “for how long”
Reference Flow:
1 second of processing time for a specified load
level of a unit manufacturing process for a
specified material based on a working scheme of
2000 hours/year. The system boundaries include
the actual machining modes, as well as the
allocated part of the non-productive modes.
Guidance for new ISO standard 14955 (Environmental evaluation of machine tools)
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Critical comparison of methods
Duflou, J.R., Kellens, K., Renaldi, Guo, Y., Dewulf, W. (2012),
Critical comparison of methods to determine the energy input for
discrete manufacturing processes, CIRP Annals, Vol. 61/1.
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
2b. Case Study - In-Depth Approach
Electrical Discharge Machining
Karel Kellens
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Case study (In-Depth Approach): Electrical Discharge Machining
Time Study – Die Sinking
Supporting
Mode
25%
Operational
Mode
66%
Standby
Mode
9%
standby mode: e.g. process waiting for operator
supporting tasks mode: e.g. workpiece
supporting mode: e.g. clamping, tool change,
tank filling, calibration…
operational mode: e.g. material removal:
roughing and finishing operations
Kellens, K., Renaldi, Dewulf, W., Duflou, J.R. (2011), Preliminary
Environmental Assessment of Electrical Discharge Machining,
18th CIRP LCE2011 Conference, Braunschweig.
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Case study: Electrical Discharge Machining
Power Study
Die Sinking EDM
Wire EDM
4
Power [kW]
3
Other
Fans & Lightning
2,5
2
1,5
1
0,5
0
Drives
Generator
Pump
Power [kW]
3,5
5
4,5
4
3,5
3
2,5
2
1,5
1
0,5
0
Other
Fans
Drives
Generator
Filling pump
Filtration pump
Supporting pump
High pressure pump
Pumps are the dominant electrical energy consumers.
Die Sinking EDM: up to 72%, Wire EDM: up to 65%
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Case study: Electrical Discharge Machining
Consumable Study
Die Sinking EDM
Wire EDM
Micro EDM
Compressed Air
1 l/min (6 bar)
1 l/min (6 bar)
4,8 l/min (6 bar)
Dielectric
Hydrocarbon Oil
10 l / week
Replacement each year
De-ionized water
10 l / week
Replacement each year
Hydrocarbon Oil
0,45 l / week
Replacement each year
Dielectric filters
Replacement every 200 hours
De-ionization Resin
/
Replacement each year
/
Cooling water (10-15°C)
6 l/min
6 l/min
2 l/min
Air filters
Others
Replacement every three months
Lubrication Oil
0.5 – 1 l / Year
Grease: 250 g/Year
Wire Guides
Grease: 100 g/Year
Wire electrode for
shaping
Note: Based on a working scheme of 2000 hours/year (250 days with 1 shift)
+ Removed workpiece material (W) as well as the tool electrode wear (T)
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Case study: Electrical Discharge Machining
Emission Study
Based on PhD-Thesis S. Evertz (2003 – RWTH Aachen):
Electrical Discharge Machining: exposure assessment using emission and immission based monitoring
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Case study: Electrical Discharge Machining
Impact Assessment
Distribution of the environmental impact during 1 hour of EDM roughing (copper electrode, hard metal workpiece)
Total of ~ 450 mPts
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Case study: Electrical Discharge Machining
Impact Assessment
Distribution of the environmental impact during 1 hour of EDM roughing (copper electrode, hard metal workpiece)
Compressed Air
0,1%
Lubrication
0,1%
Energy
Consumption
Process Cooling
19,4%
Energy
Consumption
Exhaust System
3,9%
Energy
Consumption
EDM Process
47,3%
Process
Emissions
0,0%
Dielectric
(Production +
EOL)
23,1%
Removed
Workpiece
Material
1,0%
Electrode
Material
5,1%
Electrical Energy and Dielectric main contributors to environmental impact.
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Process Models: Framework
Kellens, K., Renaldi, Dewulf, W.,
Duflou, J.R. (2012), Environmental
impact modeling of discrete part
manufacturing processes, 19th CIRP
LCE2012 Conference, Berkeley.
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Process Models: Case study of Laser Cutting
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Unit Process Life Cycle Inventories
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3. Process Taxonomy
Prof. Joost Duflou
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Process Taxonomy: Extended DIN 8580
2. Forming
3. Separating
1. Primary Shaping
DIN 8580
7. Auxiliary Processes
4. Joining
5. Coating & Finishing
6. Changing Material Properties
Complete taxonomy overview available in workshop handout
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Current Coverage of Process Taxonomy
Barbara Linke
Process Name
SCREENING
Interested to join the Initiative and
cover one or more of the (missing)
processes, don’t hesitate to contact us
and / or place your sticker on this poster.
Indicate the process name here
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
4. Experiences with screening UPLCI studies
Prof. Michael Overcash
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Screening UPLCI: Experiences and Future Research
Manufacturing as Transformational Stages
Chemical and material building with transformations to macro shapes
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Screening UPLCI: Examples of the information demand
 government (GSA, 2010)
 customers (Wal-Mart, 2011)
 business-to-business participants
(Environmental Product Declarations, UL, 2011)
 product associations (NSF/ANSI, 2009)
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Screening UPLCI: Goals
 uplci blocks that are non-complex and transparent.
 a fully populated 120 unit process database.
 a rapid means of evaluating and supporting decisions for energy
improvement of advanced materials, processes, and technology in macroshape building industry.
 add material efficiency, with science-based methods that show direct energy
benefits over the whole supply chain, an important innovation.
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Material Supply Chains look like this:
PET
0.132
Ethylene glycol
0.044
Ethylene oxide
0.032
Ethylene
Oxygen
Water for rxn
p-benzenedicarboxylic
acid
0.113
0.012
Acetic acid
0.017
Water (untreated)
0.024
0.023
Naphtha
0.02
Air (untreated)
0.033
0.012
Carbon monoxide
0.009
Carbon dioxide
0.004
Water for rxn
0.004
Natural gas
0.001
Nitrogen from
air
0.002
Oxygen from
air
0.001
Water for rxn
0.001
Natural gas
(unprocessed)
0.003
Water
(untreated)
0.001
Natural gas
(unprocessed)
0.006
Water
(untreated)
0.004
Naphtha
0.074
Crude Oil
0.077
Natural gas
0.003
Water for rxn
0.001
Methanol
0.009
Oxygen from air
0.058
p-Xylene
0.073
Crude Oil
0.03
Air (untreated)
0.058
Toluene
0.074
Natural gas
0.006
Natural gas
(unprocessed)
0.001
Air (untreated)
0.002
Air (untreated)
0.001
Water (untreated)
0.001
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Life cycle of manufacture pump
ENERGY OR
CHEMICAL LOSS
AMOUNT
UNITS
PRODUCTION
ENERGY
930
MJ/PUMP
TRANSPORT ENERGY
36
MJ/PUMP
AIR EMISSIONS
58
KG/PUMP
WATER EMISSIONS
0.01
KG/PUMP
SOLID WASTES
9.3
KG/PUMP
TOTAL CHEMICAL
LOSSES
67
KG/PUMP
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Screening UPLCI: Creating UPLCI building blocks
 High production system basis.
 90:10 rule is critical.
 All unit process blocks need reasonably close similarity in order to construct
higher order manufacturing systems – LEGO® Principle.
 Generic UPLCI data build from a common framework for each unit process.
 Connect transformation LCI to supply chain LCI.
 Allocation is an infrequent issue for these transformational plants.
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UPLCI data matrix of 7
Stages of unit
process
material
operation
power
time
loss
full mode
operation
X1
Y1
Z
partial full mode
or idle
X2
Y2
standby
X3
Y3
method of
calculation
directly product
related
indirectly product
related
production related
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Screening UPLCI: Current Status
UplcI Identification
MR1
MR2
MR3
MR4
MR5
MR6
MR7
MR8
J1
J2
J3
MC1
MC2
HT1
SF1
Drilling
Shearing
Milling
Turning
Punching
Reaming
Grinding
Boring
Gas metal arc welding
Submerged arc welding
Friction stir welding
Brakeforming
Injection molding
annealing
Coolant application
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Screening UPLCI: Lessons Learned
1)
The results are just estimates that are representative (90:10 rule is
simple, but hard to transition)
2)
A knowledgeable person can create a uplci in about 1-2 weeks of
concentrated work
3)
Partial and standby time components of the 7 matrix are first riority
4)
Transparency is a major benefit in use by others as it establishes what
was assumed and how used
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Screening UPLCI Path Forward
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Building from UPLCI database
Overhead (HVAC and Lighting) for Building
Casting
Spray Painting
Inspection
Rahimifard, 2010
 integrating process and non-process energies
 each unit process has an machine area footprint
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Building from UPLCI database
 Five plant studies, 25 machines
 For each machine obtain area then use regression to get full allocated area
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Research in connecting UPLCIs
 Each unit process changes the properties of the workpiece that affect the
cumulative energy
 shape
 mass
 surface properties
 Each block is energy and mass loss per unit of unit process output (so for
each step there is a basis change)
 This concept of connection is a major part of a user interface
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Life cycle energy profile of transformations by unit processes to make a product
35
Natural Resource Energy, MJ/output workpiece
30
25
20
15
10
5
0
0
1
2
3
4
5
6
7
8
CTG Level
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Test Bed Research
 The behavior of 3-10 unit processes in sequence or recycle loops is more
than the characteristic of the single UPLCI
 Studies of aggregate and individual UPLCI field data (energy and mass
utilization) – test the system behavior
 Known as verification and improvement
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Longer term UPLCI research for transformation manufacturing
plants or corporate developments
 Alternative manufacturing plant sequences
 Process and non-process energy estimations
 Coupling with materials and chemicals supply chain
 User interfaces
 Integrating with use and end-of-life phases (impact of recycling and reuse)
 Simulation
 Optimization
 Comparative analysis of new technology
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
4b. Panel Discussion
Dr. Barbara Linke, Prof. Fu Zhao
Prof. Karl Haapala
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
4c. Industrial Collaboration
Society of Manufacturing Engineers
Kathy Looman, Prof. Michael Overcash
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Goals
1.
Introduce and facilitate use in manufacturing plants to UPLCI tools
that estimate energy and mass utilization
2.
Utilize industrial expertise to review and support unit process studies
(in-depth and screening)
3.
Test the UPLCI tools on sequences of machines in high production
facilities
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Industrial Technical Communities
 Plastics, Composites & Coatings
 Automated Manufacturing & Assembly
 Industrial Laser
 Forming and Fabricating
 Product & Process Design and Management
 Rapid Technologies and Additive Manufacturing
 Machining and Material Removal
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Path Forward
 Technical paper to all members
 Planning for webinar
 On screening UPLCI
 On in-depth UPLCI
 Pont of contact in each of the technical groups
 Review UPLCI studies
 Concept of test beds
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
5. Coffee Break
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
6. Hands-on Session
Karel Kellens and Renaldi
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Hands-on session
Group Work: Small groups of 4/5 persons based on taxonomy
 Discussion on processes within process taxonomy
 Select 1 to 3 processes within your taxonomy category
 Process inputs/outputs ?
 Production modes ?
 Process parameters ?
 3 questions in preparation of the discussion session (last agenda point)
 What are the challenges of both CO2PE-UPLCI approaches ?
 How can industry be actively involved in this effort ?
 Which funding initiatives could be useful in support of collaboration
between partners within the CO2PE!-UPLCI effort ?
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
7. Integration within LCI databases
Prof. Wim Dewulf
Wim.dewulf@groept.be
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Tool for Life Cycle Inventory (LCI) data submission
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
7. Integration within LCI databases
Data Input
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Process identification
DIN 8580 Taxonomy
Meta data
Sub-studies
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Production modes
ISO 14955
ISO 14955
Machine functions
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Time Study
Machine
functions
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Power study
Production modes
Machine functions
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Consumables
study
Production
modes
External
LCI data
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Emissions study
Production
modes
External
LCI data
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Waste streams
to technosphere
Production
modes
External
LCI data
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Unit Process Life Cycle Inventories
CO2PE! - UPLCI Workshop
7. Integration within LCI databases
Data export
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Tool output
 CO2PE! – UPLCI Database
 Single Unit Process LCI records
ISO 14955 Report
 Aggregated records
EcoSpold data format
Exchanges: overview of the flows from eco- as well
as techno sphere to the unit process and vice versa.
Allocation: where relevant, procedures and
allocation factors for exchanges of multi functional
unit processes should be described.
Process information: description of the reference
unit (functional unit), time period, geography,
technology and dataset information.
Modeling
and
Validation:
describes
the
representativeness of the data set, sources (e.g.
literature) and validations (e.g. reviewers)
Administrative Information: documents involved
persons, originator and the published source of the
dataset.
Source: http://www.ecoinvent.org
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EcoSpoldAccess
Excel  Ecospold V1
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Dissemination channels targeted
 Single Unit Process LCI records
 CO2PE! – UPLCI Database
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Unit Process Life Cycle Inventories
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8. Future action items and Discussion
Prof. John Sutherland, Prof. Janet Twomey
Prof. Jacqueline Isaacs
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Future Action and Discussion

Feedback on the major concepts, improvements, and potentially missing
elements of the two CO2PE-UPLCI efforts.

Industrial participation concepts and collaboration.

How specifically will the audience participate and what funding initiatives
might arise to help with the CO2PE-UPLCI effort.
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Discussion
Suggestions ?
Remarks ?
Comments ?
Questions ?
Thank you for your attention!
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