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Case Study: Refrigerator
YAGITA Hiroshi
Research Center for Life Cycle Assessment
National Institute of Advanced Industrial Science and Technology
E-mail: yagita.h@aist.go.jp
How to do LCA
Case Study - Refrigerator
Case Study of Refrigerators
Goal and Scope
Comparison of Refrigerators
using CFC-11 / 12
using Alternatives
CO2 emissions in Japan
How to do LCA
Case Study - Refrigerator
Foreground Data
Manufacturing Use Disposal
Materials
Electricity Fuels
Mining
Back ground Data
How to do LCA
Raw material procurement
Material manufacturing
Parts production
Product assembly
Product transportation
Product use
of the system Intermediate treatment
The boundary
Reclamation
Waste management
Establishing Boundaries of the System
How to do LCA
Case Study - Refrigerator
System boundary
Imported
from the port of the production countries
Domestic
from the production facility excluding
transportation
Industrial materials imported
(as percentage of materials used)
100% of aluminium ingot
65% of naphtha
How to do LCA
Case Study - Refrigerator
Materials used for a refrigerator (including packaging)
Weight Assumption for
Materials Before regla- After regla- calculation
Painting 10.31 10.82 Plating + hot roll
Platting 11.18 11.07 Elect :non-elect
Stainless 0.24 0.56
Electromagnetic
Cold rolling
Others
2.96
8.62
3.59
Cool Medium
2.95
8.73
4.10 cold rolling
Steel total
Wire
36.90
1.38
CFC-12
38.22
1.56
HFC-134a
Pipe 1.80 1.68
Copper total
Aluminium
3.18
0.98
CCl2F2
3.24
1.07
C2H2F4
Other Metals 0.07 0.07 ignore
ABS 6.27 6.19
PS 8.71 8.65
PP
PE
8.55
0.40
Foam Agent
8.66
0.40
PVC 2.20 2.20
PET
Thermoplastic resins
0.01
1.38
CFC-11
0.01
1.40
HCFC-141b
PS
PUR
Phenol resins
6.82
0.06 CCl3F
7.66
0.06 C2H3ClF4
PUR
Polyester resins 0.00 0.00 PUR
Acrylic resins 0.14 0.14 PUR
Thermosetting resins 0.16 0.16 PUR
Cool CFC-12 0.20
medium HFC-134a 0.18
Foam CHC-11 0.84
agent HCFC-141b 0.69
Oil mineral 0.18 ignore
Polyester 0.24 ignore
Glass 0.24 0.24
Wood 0.34 0.33
Corrugated cardboard 6.53 6.76
Others 1.70 1.81 ignore
Total 85.86 88.38
How to do LCA
Case Study - Refrigerator
Utilities for manufacturing
Utilities before after
electricity kWh 70.76 70.76
heavy oil l 1.83 1.83
kerosene l 0.41 0.41
Urban gas m3 2.19 2.19
LPG m3 5.45 5.45
How to do LCA
Case Study - Refrigerator
Transportation from factory to households
before after
Diesel
l 4.68 4.68
(10t truck)
Electricity consumption for use
before after
Electricity kWh/month 63.4 66.7
12years for life kWh 9129.6 9604.8
How to do LCA
Case Study - Refrigerator
Disposal
Shops
30km
Collecting
50km
Crashing
10km
Fe/Al/Cu recovery
Landfill
How to do LCA
Case Study - Refrigerator
Energy consumption of a facility for demolition
Input Quantity
Electricity appliances 1,000 ton/day
Electricity 1.55×104 kWh/day
Diesel 600 l/day
How to do LCA
Case Study - Refrigerator
Energy consumption for landfill
Input Quantity
Waste 1kg
Diesel 9.4×10-4 l
Electricity* 2.0×10-3 kWh/kg
* for waste water treatment
How to do LCA
Case Study - Refrigerator
Decomposition of CFC-11 and 12
CFC-11 CFC-12
Input
Ca(OH)2 kg 0.00123 0.0014
HCl (35%) kg 0.00007 0.00008
Water kg 0.033 0.033
electricity kWh 0.650 0.650
diesel m3 0.00018 0.00018
Output
fluorite kg 0.00028 0.00064
CaCl2 kg 0.00120 0.00091
CO2 Nm3 0.000162 0.000184
How to do LCA
Refrigerator
Acrylonitrile-Butadiene-Styrene copolymer resin
Plastic ABS Butadiene Butane
CH2=CH－CH=CH2 C4H10
Butene
Styrene C2H5CH=CH2
CH=CH2
Acrylonitrile
CH2=CHCN
How to do LCA
Case Study - Refrigerator
Input materials
Propylene 1.19 kg
CH3CH=CH2
acrylonitrile 1kg
Ammonia 0.47kg CH2=CHCN
NH3
Input Output
Electricity 0.2 kWh waste water 2.6 kg
cooling water 0.3 kg
process water 2.3 kg
How to do LCA
Case Study - Refrigerator
Input materials
Acrylonitrile 0.22 kg Acrylonitrile-Butadiene-Styrene
copolymer resin
styrene 0.60 kg ABS 1kg
butadiene 0.17 kg
Output
Input
BOD 0.00098 kg
Electricity 0.71 kWh COD 0.014 kg
steam 1.7 kg SS(Suspended Solid) 0.000035 kg
cooling water 330 kg prod. Waste unspecified 0.0077 kg
heavy oil 1.046 MJ
catalyst 0.0013 kg
chemicals 0.0285 kg
additives 0.030 kg
Refrigerator Data Tree Structure for Refrigerator
Production Use Disposal
Plastic ABS Butadiene Butane Natural gas
PS Styrene Butene Oil
PP Acrylonitrile
PE Toluene Others
Elect.
PVC Elect.
PET Heavy oil Steam
PUR Steam
Steel Percoated steel sheet ABS: Acrylonitrile-
Hot-dip zinc-coated carbon steel sheet
Electrolytic zinc-coated carbon steel sheet Styrene-Butadiene
Stainless steel sheet copolymer resin
Flat rolled magnetic steel sheet PS: Polystyrene
Cold rolled steel sheet PP: Polypropylene
Copper
PE: Polyethylene
Aluminum PVC:Polyvinylchloride
CFC PET: Poluethylene
Glass terephthlalte
Wood PUR: Polyurethane
Paper
CO2 emissions [kg-CO2/kg]
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
How to do LCA
precoated steel sheet
electrolytic zinc-coated
carbon steel sheet
Case Study - Refrigerator
hot-dip zinc-coated
carbon steel sheet
stainless steel sheet
flat rolled magnetic
steel sheet
cold rolled steel sheet
copper
aluminum
ABS
PS
PP
PE
PVC
PET
PUR
CFC
glass
From process
CO2 emissions for the production of materials
wood
From elect. prod.
paper
How to do LCA
Case Study - Refrigerator
CO2 emissions (kg-CO2 / refrigerator)
Before regulation After regulation
Total 4,070.74 4,274.55
Manufacturing 216.43 (5.32 %) 220.47 (5.16 %)
Steels 51.81 52.40
Plastics 78.12 78.92
Copper 4.02 4.09
Aluminum 1.98 2.16
Glass 0.46 0.46
Paper 10.91 11.29
Wood 0.04 0.04
CFCs or HFC / HCFC 2.74 4.76
( sub total ) (150.08) (154.12)
Assembly 51.60 51.60
Transportation 14.75 14.75
Use ( electricity ) 3,851.09 (94.60%) 4,051.56 (94.78%)
Disposal 3.23 (0.08 %) 2.52 (0.06 %)
Shredder 0.64 0.66
Reclaiming 0.11 0.11
Water treatment 0.04 0.04
Transportation 1.66 1.71
(sub total ) (2.45) (2.52)
CFCs decomposition 0.78
How to do LCA
Case Study - Refrigerator
production of materials 3.7%
assembly & transportatiom 1.6%
disposal 0.08%
use 94.6%
CO2 emissions in the life cycle of a refrigerator
How to do LCA
Case Study - Refrigerator
wood 0.03%
glass 0.3% CFCs 2%
paper 7%
aluminim 1.3%
copper 3%
steel 34%
plastics 53%
The ratio of CO2 emission from the Production
of materials used in a refrigerator
How to do LCA
Methodology
System Boundary
System Boundary
Elementary flow
Raw material Elementary flow
extraction
Other
systems Transports
Product Elementary flow
Production
flow
Use
Energy Elementary flow
supply
Elementary flow Recycling/ Product Other
Reuse flow systems
Elementary flow
Waste
treatment
How to do LCA
Material
extraction Production Use
Other system
Reduce
Fossil fuel Reuse
Reduce Recycle
Thermal recycle Reduce
Energy Waste
treatment
ABC DEFG HIJKLM NO PQ RSTUVWXYZ
Natural energy
Reduce
Economy Law Moral
How to do LCA
15
CO2 Emission [kg-CO2/kg-material]
13.62
Production 1.86
in Japan
10
Overseas
Transportation
11.63
5
2.27
1.07 1.08 1.38
Mining 0.46 0.06 0.11
0.13 0.74 0.04 0.98 1.14 0.13
0
Aluminum Cu Steel PE
CO2 emissions for the production of
Aluminum, Copper, Steel and PE
How to do LCA
0.5
CO2 Emission [kg-CO2/kWh]
0.438 0.438
29.1% LNG
0.127
Combustion
0.014
22.5% Coal 93.6%
0.100
0.001
48.5% Oil
0.211 Transportation
0.01
1.9%
0.005 0.020 Mining 4.5%
CO2 emission for the production of electricity in Japan
How to do LCA
Methodology
System Boundaries-ISO14040
-System boundaries determine which unit
processes shall be included within the LCA.
-The selection of inputs and outputs, the level of
aggregation within a data category, and the
modeling of the system shall be consistent with
the goal of the study.
-The criteria used in establishing the system
boundaries shall be identified and justified in the
scope of the study.
How to do LCA
Methodology
Allocation
CO2
Cu Ore Cu
Cu Production
H2SO4
Energy Smelting
Mud
H2SO4 and/or Mud is useful or not.
If useful, CO2 is allocated depending
on weight or cost.
How to do LCA
Methodology
Allocation-ISO14040
Allocation procedures are needed when
dealing with systems involving multiple
products (e.g.multiple products petroleum
refining).
The materials and energy flows as well as
associated environmental releases shall be
allocated to the different products according
to clearly stated procedures which shall be
documented and justified.
Allocation based on Weight
How to do LCA
- same environmental load for each product -
CO2： C kg
Product A: A kg
CO2emission=C・A/(A+B)
→for 1kg; C/(A+B)kg-CO2/kg-A
Product B: B kg
CO2emission=C・B/(A+B)
→for 1kg C/(A+B)kg-CO2/kg-B
How to do LCA
Mining, Beneficiation
domestic in aboard
Concentrate Transportation
Cu matte process SO2
Cu matte H2SO4
SO2
Converter
Blister Cu
Anode furnace
Anode Cu
Electro-refining
Electrolytic Cu
Fig. Material flow for producing electrolytic copper
How to do LCA
Cu matte 1.240 kg →
scrap 0.259 kg → Converter → Blister Cu 1.000 kg
(a)
SiO2 0.102 kg → → SO2 0.516 kg
Oxygen 0.024 m3 →
Electricity 0.109 kWh →
(b) Cu matte 0.818 kg →
scrap 0.171 kg → Converter
SiO2 0.067 kg → → Blister Cu 1.000 kg
Oxygen 0.016 m3 →
Electricity 0.072 kWh →
Fig. Inventory for the production of blister copper and SO2
To avoid allocation ① fractionation of the process
Sintering Chrome, organic solvent Emissions of environmental loads
Blast furnace, converter
Chrome
coated coil
Coke oven
Casting, rolling Coating Process
Organic compound
Coated coil
Emissions of environmental loads
Coating process
Sintering chrome
Blast furnace, converter Chrome Chrome
coating coated coil
Coke oven
Casting, rolling
Organic compound Organic compound
coating Coated coil
Organic solvent
Emissions of environmental loads
参：LCA実務入門
To avoid allocation ② Expansion of the system boundary
(introducing the substitute system)
Emissions of environmental loads: a
A
The investigated system C
B
Emissions of environmental loads: b
The substitute system D B
Emissions of environmental loads: a-b
C
The target system A
-D
How to do LCA
CO2 e kg
Allocation
A a kg C c kg (\ x /kg)
B b kg D d kg (\ y /kg)
mass price
CO2 e/(c+d) kg CO2 e(cx+dy)/x kg
A a/(c+d) kg A a(cx+dy)/x kg
C 1 kg C 1 kg
B b /(c+d) kg B b(cx+dy)/x kg
CO2 e/(c+d) kg CO2 e(cx+dy)/y kg
A a/(c+d) kg A a(cx+dy)/y kg
D 1 kg D 1 kg
B b /(c+d) kg B b(cx+dy)/y kg
How to do LCA
2.5
allocated by mass
allocated by price
2.0
CO2 emission [kg-CO 2/kg]
1.5
1.0
0.5
0.0
Poly vinylidene HCl Poly vinylidene HCl (35%)
chloride chloride (35%)
Effect of allocation methods on poly vinylidene chloride production
How to do LCA
Case 1 Benzene
BTX P1 Toluene
Mixed xylene P2 p-Xylene
En 1
En 2
Case 2 Benzene
Benzene
Toluene P1’
Toluene
En 1
BTX P0
Mixed xylene P2 p-Xylene
En 2
How to do LCA
2.5
case 1
case 2
2.0
CO2 emission [kg-CO2/kg]
1.5
1.0
0.5
0.0
Benzene Toluene P-Xylene
The effect of allocation on BTX extraction process evaluation
How to do LCA
Cut-off (rule)
When and why cut-off is done?
The process is unnecessary from the purpose of the
LCA case study
The process is not important in the target product
system
When the measurement technique is not existed, or
data collection is extremely difficult because of the
system is complicated
How to do LCA
Example of the cut-off rule (thinking)
① Weight
The material or component less than 0.1 % of the
total weight
② Energy
The process less than 0.1 % of the total electricity
consumption
③ Environmental load
The process less than 0.1 % of the total CO2
emission
