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LCA Best Practices for GreenCo CompaniesCII- GreenCo Summit 2017, Pune

Dr. Rajesh Kumar SinghManaging Directorthinkstep Sustainability Solutions Pvt. Ltd., India

Copyright (c) (2015) thinkstep AG – All rights reserved

• Hot-spots identification in the value chain• Identifying short term/long term projects• Environmental responsible design and sustainable growth• Material selection and major design decisions• Benchmarking with peers/competitors • Future scenario modelling for target setting, marketing and branding• CII GreenCo and GreenPro• Voluntary requirements (BRR- SEBI, ISO 14001:2015, Customer Demand,

Responsible care, GRI G4, CDP, DJSI)• EPD and Communication• Export Markets- Product Environment Footprint (PEF), End of life of Vehicles

(ELV), Customers Demand• OFIs in supply chain• Other Indian sustainability awards requirements

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LCA Drivers- Greenco Companies

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• Cross functional team (Environment, R&D, Utilities, supply chain, Operations etc)

• Goal and scope definition (cradle to grave or cradle to cradle), functional unit• System Boundary- foreground and background processes• Foreground processes- breakdown in various units• Data collection questionnaire• Data collection and validation/consistency check• Allocation, biogenic, recycled content, EoL etc.• Development of LCA model in GaBi software• Modelling check• Generation of results for life cycle phases, by major contributors, process-

wise etc• Interpretation and significance assessment• Scenario assessment• Recommendations

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LCA Approach

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India References

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GaBi Software

• 90% Indian LCA service and software market share

• 10 years in Indian market and more than 75 LCA studies

• 50+ Leading Indian companies rely on GaBi Software

• 30 Academy Licenses• 10 Government Institutions• More than 1000 Students and

researchers

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Case Study: Godrej Locks

Reduction of compressed air Reduction

in scrap

Use of renewable

energy

Sourcing of recycled materials

Redesigning of lock

components

91.7%

93.1%

96.3%

81.9%

47.7%

91.7%

75.4%

93.4%

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Acidification Potential (AP) [kg SO2-Equiv.]

Eutrophication Potential (EP) [kg Phosphate-Equiv.]

Global Warm ing Potential (GWP 100 year s) [kg

Hum an Toxicity Potential (HTP inf.) [kg DCB-Equiv.]

Ozone Layer Depletion Potential (ODP, steady state)[kg R11-Equiv.]

Photochem. Ozone Creation Potential (POCP) [kgEthene-Equiv.]

Total fr eshw ater consumption (including r ainw ater)

Prim ary energy dem and from ren. and non ren.resources (net cal. value) [MJ]

Brass to CRCA Steel Base

Source: SUSTAIN 2016 Customer Presentation by Godrej Locks

Case Study: L&T Process Gas Boiler

• Objective: To evaluate the “cradle-to-gate lifecycle” i.e.from raw material acquisition, material production,transport, assembly and fabrication data for Process GasBoiler system in order to calculate life cycle inventories(“Life Cycle Inventory” or ”LCI”).

• To fulfil the requirements of GreenCo Rating system• Focus on electricity, scrap yield, furnace improvement

Raw material acquisition

Material processing

Production

Use and maintenance

End-of-life

Life

Cyc

le S

tage

s

Global Warming Potential

Process gas Boiler Assembly

Riser & Down comer piping

Steam Drum General Assembly

Total freshwater consumption

Process gas Boiler Assembly

Riser & Down comer piping

Steam Drum General Assembly

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Case Study: AIGMF

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Impact Category Credit EnergyDisposal and Recycling

Downstream Transport

Primary Packaging

Secondary Packaging

Upstream Transport

Container Glass -11% 7% 4% 100% -2% 2%

PET 0% 19% 2% 82% -4% 1%

Beverage Carton -12% 134% 8% -16% -15% 1%

Al Can 0% 2% 1% 93% 3% 0%

Source: http://www.indialca.com/pdfs/ILCM-2012-Session-6-Vinay-Saran.pdf

Focus on Glass light weighting, Increase in cullet content, reuse, furnace efficiency improvement

Crop cultivation

Oil seeds / rice

Drying of seeds / rice

bran production

Oil Extracti

on

Cradle to grave

Transport Use EoL -packaging

Case Study: Marico Limited

Strategy: Integrate sustainability considerations throughout the product life cycle byinstitutionalizing innovation within organization and stakeholders.

Focus on sustainable agriculture, mill yield improvement, Biomass power and steam, packaging optimisation

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Case Study: Tata Motors

• Quantification of life cycle environmental impacts and run various scenarios forresource efficiency

• Getting Vendors on Board• LCAs of several vehicles including the Safari, Ace CNG and the ACE diesel.

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Source: http://economictimes.indiatimes.com/industry/auto/real-green-cars-now-tata-motors-has-stepped-out-of-box-with-its-lifecycle-assessment-of-cars/articleshow/49145219.cms

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Case Study: ITC Limited

Life Cycle Assessment of Copier PaperFunctional unit of this LCA study is 1 corrugated container of copier paper, whichis equivalent 24.26 Kg or of 5000 A4 sheets of 75 gsm

• 135.5 Kg of CO2 emission in the life cycle of 1 corrugated container ( 5000 A4sheets ) of copier paper

• 195 kg is sequestered by our forestry project making the product a carbonpositive one

• 1018 liters of fresh water is used for making one functional unit. Around 60%of this water is returned to the environment

• 44% of the total energy required is met by renewable sources

13Source: www.greenco.in/site/mmbase/attachments/427402/ITC

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• JSW Steel Limited

(https://epd-online.com/EmbeddedEpdList/Download/8955)• Saint-Gobain Gyproc India

(http://gryphon.environdec.com/data/files/6/10162/epd538%2012.5%20mm%20Gypboard%20Plain.pdf)

• Ambuja Cements Limited (Internal)

Case Study: EPDs in India

Case Study: EPD- JSW Steel

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Case Study: JSPL Limited

Life Cycle Assessment of Plate Product

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Case Study: Mahindra Sanyo Special Steel

Impact IndicatorsRaw Materials

Transport Manufacturing

Use Phase

End-of-LifeDRILime Oxygen

Ferro Alloy Electricity Aluminium Scrap

Abiotic DepletionAcidification PotentialGlobal Warming PotentialHuman Toxicity PotentialPhotochem. Ozone Creation PotentialPrimary energy demand

Water ConsumptionWaste Generation

Highly Negative Negative Neutral Positive

GoalIdentification of environmental and social material issues in the value chain E-LCA conducted as per ISO 14040 and ISO 14044 requirements and S-LCA framework designed using UNEP-SETAC guidelines and adapting to Indian contextScopeLife cycle stages included are materials, transport, manufacturing, end-of-lifeFunctional UnitE-LCA: Production of 1 ton of special steel S-LCA: Steel product manufactured at Khopoli manufacturing location of MSSSPL located at Maharashtra, India

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Case Study: Mahindra Sanyo Special Steel

End-of-LifeDRI Electrode Oxygen Ferro Alloy HFO Electricity Iron Ore Recycler Dealer Customer EOL Scrap

Local Employment Created

Education Index

Electricity

Complaints by communities

Spendings on cultural activities

Skill Development

Spendings on sports amenities

Infrastructure

Water Availability

Health Index

Sustainability / environmental reporting

Mortality Rate

Water Facillities

Incidents of consumer health & safety

Customer Satisfaction

Income Index

Incidents of Corruption

Support to Local Suppliers

Anti-Competitive Risk

Lost Time Injury Frequency Rate (LTIFR)

Discrimination on Wage

Human Rights Complaints

Forced Labour Risk

Child Labour Risk

Employees Receiving Minimum Wages

User PhaseImpact Indicators

Raw MaterialsTransport Manufacturing

Case Study: Hindalco Industries

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-20% 0% 20% 40% 60% 80% 100%

Primary energy demand(net cal. value) [MJ]

Photochem. Ozone Creation Potential (POCP) [kg Ethene-Equiv.]

Ozone Layer Depletion Potential (ODP) [kg R11-Equiv.]

Global Warming Potential (GWP 100 years) [kg CO2-Equiv.]

Eutrophication Potential (EP) [kg Phosphate-Equiv.]

Blue water consumption [kg]

Acidification Potential (AP) [kg SO2-Equiv.]

Abiotic Depletion (ADP elements) [kg Sb-Equiv.]

Life Cycle Impact Categories per tonne of Aluminium Cold Rolled Strips

Bauxite Production Alumina Production Anode Production Electrolysis Cast House Hot Rolling Scalping

Hindalco LCA Profile benchmarked with EU and US Average Profile

Focus on renewables, Bauxite quality, reuse, furnace efficiency improvement

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Case Study: Arvind Limited

Challenge• Sustainability Management System• Understanding the environmental impact of

organically grown cotton fibre • Understanding the environmental impact of various

textile technologies

Solution• Implementation of thinkstep’s SoFi software for

corporate sustainability data and performance management

• LCA of cotton fibre (conventional, BCI and organic) based on primary data

• Thinkstep’s agricultural model and experience allows in-depth assessment and benchmarking

• LCA of Denim, Shirt produced through various technological routes

• Focus on agriculture practices, dyeing technology, energy efficiency improvement, chemicals

GoalQuantification of life cycle environmentalimpacts for one “mHawk Engine”manufactured at Igatpuri plant of Mahindra andMahindra over the cradle to grave systemboundary as per ISO 14040/44 standard

Function Unit“1 MHAWK engine weighing xx kg over thecradle to grave system boundary, which will beused in a Scopio car having fuel efficiency ofxx km/L and life of 300000 km”

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Case Study: Mahindra Engine

Focus on light weighting, improvement in power traintechnologies, scrap yield, electricity consumption

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About thinkstep

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Product Sustainability Solutions

GaBi Training & workshops

Increase knowledge and expertise from basic to

expert user.

EPD Development

Turn-key service for EPD development

(HPDs can be offered)

LCA Services

LCA ScreeningComparative LCA

ISO Compliant LCA PEF

Services

Software

ContentGaBi Professional & Extension Databases

3rd Party LCA Database ecoinvent

Trucost NCA Factors

GaBi tsSoftware

Drive productsustainability during design and planning providing modelling,

reporting and diagnostic tools.

GaBi DfX

Rapid analysis of products containing complex

assemblies right from BoM.

GaBi Server

Collaborate on projects,

improving quality assurance and

return on investment.

GaBi Envision

Quick evaluation of ‘what-if’ scenarios, optimising product

design and communication of

performance.

PSRT

Join top product sustainability leads and openly share and learn.

LCA Hub

Data collection application to

accelerate LCA, increase data

quality and consistency.

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Hauptstraße 111-113 •70771 Leinfelden-Echterdingen •Germany

Phone: +49 711 341817-0Fax: +49 711 341817-25

info@thinkstep.comwww.thinkstep.com

25

421, MIDAS, Sahar PlazaAndheri Kular Road Andheri East Mumbai 400059

Hauptstraße 111-113 70771 Leinfelden-Echterdingen Germany

Dr. Rajesh Kumar Singh

Phone: +91 22 4266 7693 Mobile: +91 97550 19145

Rajesh.Singh@thinkstep.com