LCE 2016 BERLIN - ecoPROSYS Presentation by A.J. Baptista

22nd – 24th May 2016

Organized by: In cooperation with: Sponsored by:

ecoPROSYS: An eco-efficiency framework applied to a medium density fiberboard finishing line

A.J. Baptista, E.J. Lourenço, J.P. Pereira, F. Cunha, E.J. Silva, P. Peças

António J Baptista

[email protected]

AGENDA

Introduction

ecoPROSYS methodology description

Case study description and results

Conclusions and remarks

Introduction

Objectives

• Identification and evaluation of unit processes and production systems for its eco-efficiency performance

• Connection of the eco efficiency principles with the appropriate environmental aspect

• Identification and quantification of the variable(s) or key aspect(s) that affect eco-efficiency performance;

• Life Cycle Assessment and Life Cycle Cost Assessment integration

• Identification of the significant environmental aspects;

• Definition of eco-efficiency improvement strategies;

• Quantification of eco efficiency performance variations / evolution

Eco-Efficiency Integrated Methodology for Production Systems: ecoPROSYS©

Introduction

ecoPROSYS© is a new eco-efficiency approach that comprehends the continuous joint developments of a team of entities integrated in the PRODUTECH Cluster

Reduce material intensity

Reduce energy intensity

Reduce dispersion of toxic substances

Enhance recyclability

Maximize use of renewable resources

Extend product durability

Increase service intensity

7 Principles

Eco-EfficiencyProduct, process or service value

Environmental influence=

Introduction


Eco-Efficiency Profile

Process Mapping

Goal and Scope DefinitionDetermination of system boundaries

Identification and sequence of stagesDefinition of functional unit

Definition of system model (flows)

ProcessMapping



ProcessMapping

• Environmental Performance Assessment (EPA)

• Life Cycle Assessment (LCA)

• Value Modelling

ecoPROSYS Pillars:


No Eco-efficiency PrincipleLow

intensityIntense

Highintensity

P1 Reduce material intensity 1 3 5

P2 Reduce energy intensity 1 3 5

P3 Reduce dispersion of toxic substances 1 3 5

P4 Enhance recyclability 1 3 5

P5 Maximize use of renewable resources 1 3 5

P6 Extend product durability 1 3 5

P7 Increase service intensity 1 3 5

EPA – Input Flows

Aspect Group Aspect P1 P2 P3 P4 P5 P6 P7 F S R E

Materials Paint 5 1 3 3 1 5 1 5 5 25 3

Materials Hardener 5 1 3 3 1 5 1 5 5 25 3

Energy Electricity 1 5 3 1 3 1 1 5 5 25 5

EPA – Output Flows

Aspect Group Aspect P1 P2 P3 P4 P5 P6 P7 F S R E

ResiduesPaint

Packaging3 1 5 5 1 1 1 3 5 15 3

ResiduesHardenerPackaging

3 1 5 5 1 1 1 3 5 15 3

Air emissions VOC 3 1 5 5 1 1 1 3 5 15 3

Environmental intensity and significance Parameterization

F = Frequency

S = Severity

R = Risk = F * S

E = Extension

ISO 1

40

01

Environmental Performance Assessment


No Eco-efficiency PrincipleLow

intensityIntense

High intensity

P1 Reduce material intensity 1 3 5

P2 Reduce energy intensity 1 3 5

P3 Reduce dispersion of toxic substances 1 3 5

P4 Enhance recyclability 1 3 5

P5 Maximize use of renewable resources 1 3 5

P6 Extend product durability 1 3 5

P7 Increase service intensity 1 3 5

Significance = P * R * E

Significance Analysis – Input flows

Aspect Group Aspect P1 P2 P3 P4 P5 P6 P7

Materials Paint HS LS S S LS HS LS

Materials Hardener HS LS S S LS HS LS

Energy Electricity LS HS HS LS HS LS LS

Significance Analysis – Output flows

Aspect Group Aspect P1 P2 P3 P4 P5 P6 P7

Residues Paint Packaging LS LS S S LS LS LS

ResiduesHardener Packaging

LS LS S S LS LS LS

Air emissions VOC LS LS S S LS LS LS

Environmental intensity and significance Parameterization

Environmental Performance Assessment



ProcessMapping • Environmental Performance Assessment (EPA)


• Value Modelling

ecoPROSYS Pillars:


Free available databases

• ELCD• APME - Industry data 2.0• LCA Food DK• US LCI• GREET• ALCAS• SPINE@CPM• IISI• GTGLCI• GEMIS• …

ToolDatabase

Input Categories

Impact 2002+

ImpactCategories

DamageCategories

Life Cycle Assessment (LCA)


Characterisation

ToolDatabase

Output

Input Categories

Impact 2002+

LCA Results

EnvironmentalInfluence

Impact 2002+

Input by user

ImpactCategories

DamageCategories

Calculation

Type of material

Type of energy

Type of resource

Type of residue

Type of emission

Amount

Amount

Amount

Amount

Amount

ProcessMapping



ProcessMapping • Environmental Performance Assessment (EPA)


• Value Modelling

ecoPROSYS Pillars:


Materials

Energy

Resources

Residues

Equipment

Labour

Standard accounting

systemindicators

Financial investmentsSalesOperating subsidiesSupplies and external servicesLabour costs…

GAV

EBITDA

Gross productionvalue

…

Value Modelling



Significantenvironmental

aspects

Life cycleassessment

Valuemodelling

Environmentalperformance assessment

ProcessMapping

Environmentalinfluence

(KEPIs)

Valueindicators



ecoPROSYS ProfilesEnvironmental Profile

Indicator Value

Materials and Raw Materials 780 kg

Total Energy 10.000 kWh

Water consumption 2,27E-02 m3

Residues (total) 29 kg

GHG Emissions 6580 kg CO2 eq.

Acidification 65 kg SO2 eq.

Electricity 0,49 Pts

Materials and Raw Materials 0,71 Pts

Residues incineration 0,0021 Pts

Environmental Influence (Total) 2,41 Pts

Value Profile

Indicator Valor

EBITDA 150,00 €

GAV 400,00 €

Sales 500,00 €

Production time 475 hours

Product Durability 40 years

Eco-eficiency Profile

Eco-eficiency Principle Environmentl AspectRatio: GAV

IA

P1 - Reduce material intensity Materials Paint 740,59

P2 - Reduce energy intensity Energy Diesel 313,79

P2 - Reduce energy intensity Energy Electricity 805,60

P3 - Reduce dispersion of toxic substances Air emissions VOCs 33256,84

Eco-efficiency (Total) 165,98




aspects


Valuemodelling


ProcessMapping


(KEPIs)

Valueindicators

Eco-Efficiency profile

Goals


Nº Eco-efficiency Principles Goal

P1 Reduce material intensity 0%

P2 Reduce energy intensity 10%

P3 Reduce dispersion of toxic substances 0%

P4 Enhance recyclability 0%

P5 Maximize use of renewable resources 0%

P6 Extend product durability 0%

P7 Increase service intensity 0%

Energy – Current Scenario

Type of Energy Quantity (kWh/year) Cost (€/year)

Electricity 2500 200

Diesel 7500 900

Energy – Alternative Scenario

Type of Energy Quantity (kWh/year) Cost (€/year)

Electricity 2250 180

Diesel 6750 810

Indicator Current scenario Alternative scenario

Energy consumption 10.000 kWh 9.000 kWh

Energy cost 1.100 € 990 €

GHG Emission 6580 kg CO2 eq. 5800 kg CO2 eq.

Acidification 65 kg SO2 eq. 58,62 kg SO2 eq.

Electricity 0,49 Pts 0,441 Pts

Environmental Influence (total) 2,41 Pts 2,35 Pts

Eco-efficiency Ratio: VABIA

165,98 170,21




aspects


Valuemodelling


ProcessMapping


(KEPIs)

Valueindicators


Goals

Continuous Improvement




aspects


Valuemodelling


ProcessMapping


(KEPIs)

Valueindicators


Goals

Simulation of alternatives and sensitivity analysis

Material andEnergy Flow

Analysis

LCC approach


Eco-

efficiency

Life Cycle Impact

Assessment

Scope & Data

Collection

Cost & Value

Assessment

Environmental

Performance Evaluation

KEPIEco-efficiency

Indicators

Cost & Value

Data

Environmental

Profile

Eco-efficiency

ProfileValue Profile

Co

nti

nu

ou

s Im

pro

vem

en

t

Indicators

Profile


Plywood boards finishing line description

Unit Process (Stages) Description

Feeding table Supply the conveyer with boards (automatically)

CalibratingConsist in calibrating the board's thickness using coarse and medium

sand paper

SandingConsist in sanding the MDF boards to obtain a smooth finish and

guarantee the specification thickness

Cutting

The cutting process consists of two steps, vertical cutting and

longitudinal cutting, during these steps the MDF boards are also

calibrated in terms of width and length

StackingDuring this unit process the MDF boards, already cut, are stacked, and

the protection board is placed on the top

PackingThis unit process is carried out by placing cardboard and the base

studs, finally the strapping PET tape placed


Plywood boards finishing line description

Description Amount (per m3) Unit

Materials MDF supplied into the finishing line 900.620 kg

Auxiliary Materials

Sandpaper 0.288 m2

Cardboard package 0.649 kg

Protective MDF board 32.420 kg

Stud (base protection) 8.230 kg

PVC strapping tape 0.240 kg

EnergyDiesel (fork lift) 0.252 kg

Electric 43.715 kWh

Water Cooling water 100 Litres

Air Emissions CO2 emissions (forklift) 0.670 kg

Wastewater Cooling water 100 Litres

ResiduesWood trimmings and dust 150.620 kg

Sand paper 0.2881 m2


Plywood boards finishing line: Results

Environmental influence of material and energy (Single score)

Environmental influence of each unit process per damage category (Single score)



Eco-efficiency profile - Unit processes

Unit processes (2) Normalized Impacts (Pt)

Normalized costs (€)

Eco-efficiency indicators

Feeding table 0.03 0.02 6.51E-01

Calibrating 0.70 0.22 3.20E-01

Sanding 0.91 0.28 3.04E-01

Cutting 0.02 0.06 3.26E+00

Stacking 1.00 0.03 2.87E-02

Packing 0.48 1.00 2.11E+00

Overall eco-efficiency indicator(3) 2,05E+03

(2) - Unit Process Production Cost/Unit Process Environmental influence

(3) - GVA/Environmental influence



Environmental Profile

Energy and materials - Environmental Influence

Material consumed 6.53E-03 Pt

Electrical energy consumed 8.26E-03 Pt

Diesel consumed 1.85E-04 Pt

Water used 8.53E-05 Pt

Global warming 4.07E+01 kg CO2 eq

Aquatic acidification 2.85E-01 kg SO2 eq

Ozone layer depletion 2.75E-06 kg CFC-11 eq

EBITDA 14.80 €/m3

GVA 30.82 €/m3

Sales 237.80 €/m3

Production cost 12.15 €/m3

Value profile



Eco-efficiency plot for MDF finishing line production system (bubble area is proportional to environmental impact - Pt)


ecoPROSYS© is a flexible standard-based methodology to assess the eco-efficiency performance of production systems

Integrates Environmental Performance Evaluation (EPA) with EnvironmentalImpact and Cost/Value assessment models through a life cycle prespective(LCA and LCC)

Generates a comprehensive set of simple and intuitive indicators (KPI andKEPI), and multiple eco-efficiency ratios

Allows the simulation of alternatives and sensitivity analysis aiming thesupport of decision making process for continuous improvement

It is structured in TWO complexity levels (ecoPROSYS Level 1 and Level 2) tobetter adjust the eco-efficiency assessment regarding the MATURITY LEVELof the company

Generates profiles of eco-efficiency assessment: Environmental Profile,Value Profile, Eco-Efficiency Profile) for inner and external comunication


ecoPROSYS© methodology was imbibed into Software Tools byMicroProcessador and SISTRADE ICT companies in the two levels ofcomplexity (ecoPROSYS Level 1 – “Base analysis” and Level 2 – “Advancedanalysis”)

There are strong foundations within the methodology for ContinuousImprovement attitude and eco-efficiency improvement of companiesprocesses

ecoPROSYS© is being used in several ongoing projects as a basis for eco-efficiency assessment, both at a Portuguese National level, but also atEuropean International level, namely with project SPIRE - H2020 MAESTRI

Total Resource and Energy Efficiency

Management System for Process Industries

Thank you for your attention

ecoPROSYS: An eco-efficiency framework applied to a medium density fiberboard finishing line

António J Baptista ([email protected])

mailto:[email protected]

LCE 2016 BERLIN - ecoPROSYS Presentation by A.J. Baptista

Environment

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