How to Develop LCI Database for Thai Industry: case study refinery products by Mr. Puttipong PATTANAKITTIPONG Engineer Focus Center on LCA and EcoProduct Development (FC eco-LCA), National Metal and Materials Technology Center (MTEC), National Science and Technology Development Agency (NSTDA) 1 Contents • Introduction: Life Cycle Assessment • Life Cycle Inventory (LCI) Data • LCI Database of Thai Industry 2 Product Life Cycle Thinking • Life cycle thinking expands the traditional focus on manufacturing processes to incorporate various aspects associated with a product over its entire life cycle. • The producer becomes responsible for the products from cradle to grave and has to develop products with improved performance in all phases of the product life cycle The life cycle of a product – and closing the loop 3 Road Map - ISO 14000 Evaluation & Auditing Tools Management Systems Product-Oriented Support Tools Environmental Performance Evaluation (EPE) ISO 14004 (EMS) Life Cycle Assessment (LCA) ISO 14031 guidelines Environmental Auditing (EA) 14010 general principles 14011-1 audit procedures 14012 qualification criteria for environmental auditors general guidelines on principles, systems & supporting techniques Environmental Labelling (EL) ISO 14001 (EMS) specification with guidance for use Other standards writers Source: Thailand Environment Institute 14041 general principles & practices 14042 life cycle inventory analysis 14043 life cycle impact assessment 14044 life cycle improvement assessment 14020 basic principles for all environmental labelling 14021 terms & definitions 14022 symbols 14023 testing & verification 14024 guiding principles, practices & criteria for certification programs ISO/IEC Guide 64 environmental aspects of product standards 4 ISO14040 LCA Definition LCA is a technique for assessing the environmental aspects and potential impacts associated with a product, process or service by: compiling an inventory of relevant inputs and outputs of a system; evaluating the potential environmental impacts associated with those inputs and outputs; interpreting the results of the inventory and impact phases in relation to the objectives of the study. 5 ISO 14040 Life Cycle Assessment, Principles and framework LCA Framework นิยามและขอบเขต ของการศึกษา การวิเคราะหบญ ั ชีขอมูล (Inventory Analysis) การประเมินผลกระทบ (Impact Assessment) การแปลความ หมายของผลลัพธ (Interpretation) การประยุกตโดยตรง • การพัฒนาและ ปรับปรุงผลิตภัณฑ • การวางแผนกลยุทธ • การกําหนดนโยบาย • การตลาด • อื่นๆ 6 LCA can 9 Assess potential environmental impacts, at both local and global scales 9 Quantify environmental impacts associated with a product/service 9 Identify the key life cycle stage 9 Identify the most significant impacts 9 Identify the main contributors 9 Best available scientific-based tool in comparisons between products/alternatives in order to identify environmentally-preferred choice 7 Applications of LCA Industry Voluntary Improvement EcoDesign Eco-Products Process improvement (ex. Recycle process) Marketing Self assertion Comparative assertion Env. Label Env. Report LCA EMS Env. administration (ex.Support for recycle) Economic & Social Administration Env. Education Lifestyle Review Green purchasing Society Consumption （Consumer’s mind) 8 Source: Inaba, AIST, Japan Basic BasicConcept ConceptofofLCA LCAand andGeneral GeneralProcedures Procedures Raw Material Acquisition Setting Settingup up Scope of Scope of Research Research Material Transportation Parts Assembly Disassembly Incineration Products Use, Repair Landfill Transportation Life-Cycle Life-Cycle Stage Stage Identification Identification ofofUnit UnitProcess Process Recycling and Reuse Recycling Inventory Analysis Inventory Analysis Estimate the environmental Estimate the environmental impact impactofofthe theproduct productlife lifecycle cycle CO2 SO2 NOx Impact Assessment Impact Evaluate theAssessment impact on the Evaluate the impact on the natural naturalenvironment environment Total nitrogen Total phosphorous Heavy metals Impact on Air Global warming Water pollution Eutrophication Identify significant Results Interpretation Results Interpretation environmental challenges LCA LCAExamination Examination and Utilization and UtilizationofofResults Results Compilation in Reports Health effects Impact on water Acidification Checking Data Critical Review 9 Source: Norihiro Itsubo Life Cycle Inventory Use Manufacturing Disposal Importance Foreground Data Materials Mining Electricity Fuels Background Data Source: INABA,10AIST LCI Database in Thailand Federation of Thai Industry Ministry of Industry (Department of Industrial Works) National Metal and Materials Technology Center Thai Environment Institute Thailand Research Fund 11 Thailand National LCI Database Basic Materials Infrastructure Energy, Utilities and Transportation Coal Petroleum Electric power Transportation system Water supply (surface / ground) Recycle and Waste Management Recycle Landfill Anaerobic digestion Incineration Industrial materials Agriculture Plastics (PS, PE, PP, etc.) Non-ferrous metals Ferrous metals Aluminum Fibers Synthetic rubber (SBR, BR) Paper Petrochemicals (7) Commodity chemicals NaOH H2SO4 HCl Cl2 Lime Na2CO3 Sulfur Cassava Cotton Corn Natural rubber Vegetable oil livestock Animal feed Sugar cane rice Building and Construction materials Steel Gypsum Cement Glass Wood Tiles 12 Steering Committee Avg.data Central LCIAvg.data Database Technical Committee#1 Technical advices 2006 First stage (MTEC) Input-Output data (actual, estimate, theory) WG1: Natural Gas PTIT WG2: Refinery Products WG3: Petrochemical Products Technical Committee#2 Industrial Specific Institutions 2007- 2008 Second stage Technical advices WG4: WG5: WG6: Ferrous/non -ferrous Transportation system Construction materials WG7: Agriculture WG8: Basic chemicals WG9: Recycle & Waste management 13 Net Work System of LCI Database Data Input Org. Central Database Registration Input Correction User Pass Word Input Search Record LCA Data-Base Pass Word ID Data Receive Data trans. Internet Server Source: Nobuhiko Narita, Japan Environmental Management Association for Industry 14 PTIT •Natural gas •Refinery products •Petrochemical products FTI and Industrial Specific Institutions •Construction Mat. •Basic chemicals •Etc. Operation Procedure USERs AVERAGE DATA AVERAGE DATA Central Database (MTEC) •Member/partner •Govermental sector •Research Institute/ University •Others AVERAGE DATA Others •Transportation •Agricultural products •Electricity •Tap water 15 LCI Database “Refinery Product” 16 Data management com. A com. B PTIT com. C Central database com. D • Develop questionnaire with MTEC • Allocate confidential data base on product • Feed average data to central database • Verify the data • Receive average data for each product • Verify/Validate the data by cross check method • Transform the average data to database format • Distribute database via internet using XML file 17 Working Process Setting Up Scope Template Preparation Gate to Gate Data Gathering Data Analysis Verification Validation National Database 18 Working Process Setting Up Scope Template Preparation Gate to Gate Data Gathering Data Analysis Verification Validation National Database 19 Scope and Boundary • Gate to Gate – Input: Material, External Energy, External Utility – Output: Product, Co-product, Pollution – Period: 2005-2006 • Product list – – – – – – – Diesel Gasoline Gasohol JET Kerosene LPG Fuel Oil 20 Scope of LCI Air emission Raw material External Fuel External Water External Electricity Product By Product Wastewater Solid Waste 21 Scope of LCI Air emission Product Raw material External Fuel External Water External Electricity By Product Process Wastewater Solid Waste 22 Life cycle inventory – Data collection • Literature information – scientific papers, public reports, LCA reports – electronic databases (part of LCA software) • Questionnaire • Calculations – based on mass balances • Measurements – product-specific data 23 Flow Diagram of Refinery 24 Source: Petroleum Institute of Thailand Air Emission Overall Data Raw Material Quantity Unit Crude oil xxx kg MTBE xxx kg Ethanol xxx kg Chemical xxx kg Catalyst xxx kg ... xxx Utilities Quantity Quantity Unit CO2 xxx kg NOx xxx kg SO2 xxx kg TSP xxx kg CFC xxx kg CO xxx kg Diesel xxx kg VOCs xxx kg Benzin 91 xxx kg Heavy Metal xxx kg Benzin 95 xxx kg JET xxx kg Kerosene xxx kg LPG xxx kg Asphalt xxx kg Sulfur xxx kg Quantity Water Emission Refinery Unit Product Unit Quantity Unit Steam xxx kg Electricity (onsite) xxx MJ BOD xxx kg Electricity (outside) xxx MJ COD xxx kg Steam xxx MJ Sulfide xxx kg Cooling water xxx m3 Oil&Grease xxx kg Potable water xxx m3 SS xxx kg Air xxx m3 TDS xxx kg Total N xxx kg Total P xxx kg Heavy Metal xxx kg ….. xxx Solid Waste Oil Sludge ….. Quantity Unit kg 25 Example of Questionnaire F2 F3 F1 U_CDU F4 Crude Distillation Unit F5 Input Inventory E_CDU Inputs Code Detail Quantity Unit Note F1 Crude oil XXXXX 1000MT From unit xxxx F_CDU Chemical xxx XXXXX Ton - …… …… …… …… …... Utilities Code Detail Quantity Unit Note U_CDU Electricity XXXXX 1000MWh - U_CDU Fuel XXXXX Ton - U_CDU Steam XXXXX ….. ….. 26 Example of Questionnaire Output Inventory Products Code Detail Quantity Unit Note F2 LPG XXXXX 1000MT - F3 TOP XXXXX 1000MT - F4 Naphtha XXXXX 1000MT - …… …… …… …… …… Quantity Unit Note - Water Emission Code Detail EW Condensate XXXXX Ton EW Wastewater XXXXX m …… …… …… …… 3 …… 27 Example of Questionnaire Output Inventory (Conti) Air Emission Code Detail Quantity Unit Note EA_CDU NO2 XXXXX ppm - EA_CDU NOx XXXXX ppm - EA_CDU SO2 XXXXX ppm - EA_CDU CO XXXXX ppm - EA_CDU CO2 XXXXX ppm - EA_CDU TSP XXXXX ppm - EA_CDU Lead - - - EA_CDU PM XXXXX ppm - …… …… …… ……. Detail Quantity Unit Note - - - …… …… ……. …… Solid waste Code ES_CDU …… …… 28 Working Process Setting Up Scope Template Preparation Gate to Gate Data Gathering Data Analysis Verification Validation National Database 29 Data Analysis • Simplify process • Check mass balance and energy balance • Allocation by energy density for each product in each process if possible • Average by production share 30 Simplify flow diagram HDT ISOM Treatment MX Gasoline/ Gasohol CCR CDU Treatment Kerosene Treatment FCCU HTU TCU BBU Fuel Gas LPG Diesel HMU HCU Gas Oil 31 Bitumen Verifying • Mass Balance • Energy Balance 32 Allocation and Averaging • Allocation: based on Energy Density • Averaging: based on production share (Horizontal) 33 Allocation and System Boundary Expansion Allocation Upstream Process Units X% X% Production System Primary Products Downstream Applications Energy and Emissions Y% Co-products Petroleum System: X = 60-70%, Y= 30-40% System Boundary Expansion Upstream Process Units 100% X% Production System Primary Products Downstream Applications Energy and Emissions Y% Co-products Downstream Applications 34 Averaging: base on production share (Horizontal) Ａ comp. Ａ1 Ａ2 Ａ3 Ａ1 A2 Ａ3 Ａ1 Ａ2 Ａ 3 ave. Ｂ comp. B1 Ｂ2 Ｂ3 ave. Ｂ1 Ｂ2 Ｂ3 Ｃ1 Ｃ2 Ｃ3 Ｂ1 Ｂ2 Ｂ 3 Ｃ comp. Ｃ1 Ｃ2 Ｃ3 ＋Ｃ 3 ave. ＋ave. ＋ave. Vertical method Horizontal method ave. Hybrid Method 35 Acknowledgement • • • • • Prof. Dr. Atsushi Inaba, Japan Mr. Fumio Tanaka, Japan Assoc. Prof. Dr. Thumrongrut Mungcharoen,MTEC Ms. Kirana Chomkumsri, MTEC Petroleum Institute of Thailand: PTIT 36 THANK YOU 37 Components of LCA Impact Assessment Goal Definition and Scoping Improvemen t Assessment Inventory Assessment 38 Advantages of LCA 9 Realistic associated environmental impacts: resource depletion, ecological and human health 9 Maximum possible impacts 9 Product-oriented environmental performance assessment 9 Best available scientific-based tool in comparisons between products/alternatives in order to identify environmentally-preferred choice 39 The Use of LCA by Industry 40