Master thesis seminar" Carbon footprint of pultruded composite products in Automotive applications
-
Upload
samer-ziadeh -
Category
Automotive
-
view
95 -
download
0
Transcript of Master thesis seminar" Carbon footprint of pultruded composite products in Automotive applications
Carbon footprint of pultruded composite products in Automotive applications: case study side panel
of a coach
Samer Ziadeh25.8.2015
Outline Introduction The aim of the case study Life cycle of the side panel The modeling and calculations Results and discussion Further work for improvements Conclusion
03.05.2023 2
Introduction• The increasing demands of the environmental protection
especially in the automotive industry.• The automotive industry is a major contributor of emitted
greenhouse gas emissions in the world.
03.05.2023Carbon trust, Carbon Footprinting guide- Carbon Trust, 2012.
3
”A carbon footprint is the total greenhouse gas (GHG) emissions caused directly and indirectly by an individual, organization, event or product, ”Carbon trust
o Kyoto GHG emissions: (CO2), (CH4), (N2O), (HFCs), (PFCs), (SF6).
o Carbon dioxide equivalent (CO2e) is a measure used to compare the emissions from various greenhouse gases based upon their global warming potential
03.05.2023 4
Emission factor CO2e
Activity data
mass/volume/energy/distance
CF of the given
activity
Standards and Labels Standards: PAS 2050, ISO/TS 14067, The GHG
Protocol: A corporate Accounting and Reporting Standard.
Labels:
03.05.2023 5
The aim of the case study• Calculating the CF and energy consumption for a
pultruded composite profile.• Comparing the values with other conventional materials.• Emphasize the benefits of light materials in weight
reduction, less fuel consumption and lower impacts on environment.
03.05.2023 6
The side panel of a coach
03.05.2023Exelcomposites.com, 'Exel Composites –
Advanced Pultrusion and Pullwinding Technologies', 2015.
7
(a) The Body component fixed on coach, Solidworks drawing of the panel (b) front and (c) back
The pultruded composite profile is 43,2% wt of E-glass fiber (GF) and unsaturated polyester resin (UP).
Pultruded profiles enviromental analysis
03.05.2023J. Anderson, Green guide to composites, Garston: BRE; Netcomposites, 2004. 8
Sandwich panel 8m x 1m(25mm core) ribs as a core materials
03.05.2023 9
Fibers for Pultrusion (CSM with glass rovings) (39%)Polyester + 50% CaCO3 (45%)Closed mixing-any matrix (<1%)Pull fibers through resin - emissions from resin bath (15%)Cure through heated die (<1%)Saw to length (<1%)Cleaning of pultrusion machine (<1%)
Life cycle of side panel
03.05.2023 10
Data collection
03.05.2023 11
Materials Thickness (mm)
Density (kg/m3)
Weight (kg)
Stainless steel, ferritic, AISI 405, wrought, annealed, low nickel
0,9 7,82x103 64,74
Aluminium, 5005, wrought, H14 2,5 2,72x103 62,56
Carbon steel, AISI 1050, annealed 0,75 7,9x103 54,51
E-glass fiber/polyester, pultruded profile (UD fiber and CSM) 90̊ direction
3 1,9x103 52,44
Eco Audit modeling
03.05.2023Cambridge Engineering Selector Software (CES 2015). Granta desgin, 2015.
12
CF and energy consumption calculationso Transportation phase: 4500 km distance
o Use phase: product life cycle 12 years, distance 200 km per day, usage 350 days per year
Life distance 840000 km
03.05.2023M. Ashby. Materials and environment. 2end
ed. Elsevier,2013. 13
Results and discussion
03.05.2023 14
Raw materials ex-traction
Manufacturing Transportation Use of the product End-of-life0
20000
40000
60000
80000
100000
120000
140000
160000
180000
9680
25100
168000
4050
174000
Energy Consumption MJ
Composite Aluminium Stainless steel Steel
03.05.2023 15
Raw materials extrac-tion
Manufacturing Transportation Use of the product End-of-life0
2000
4000
6000
8000
10000
12000
14000
507
10000
1650
11900
237
12400
CO2 footprint kg
Composite Aluminium Stainless steel Steel
03.05.2023 16
Total Carbon Footprint (kg)0
2000
4000
6000
8000
10000
12000
1400010600 10800
Composite AluminiumStainless steel Steel
Total Energy Consumption (MJ)0
20000400006000080000
100000120000140000160000180000200000
152000 153000
Composite AluminiumStainless steel Steel
The equivalent annual environmental burden (averaged over 12 year of a product life)
03.05.2023 17
Composite Aluminium Stainless steel Steel
12700
1620015100
12800
Total energy consumptions per a year (MJ/year)
Composite Aluminium Stainless steel Steel
885
11401080
900
Total CO2 footprint per a year (kg/year)
Transportation phase case scenarios
03.05.2023 18
Case scenario 1 (Truck-diesel)
Case scenario 2 (air flight -kerosene)
0100020003000400050006000700080009000
10000
278
7080
332
8450
344
8750
286
7270
Energy Consumption (MJ)
Composite Panel Aluminium PanelStainless steel Panel Steel Panel
Case scenario 1 (Truck-diesel)
Case scenario 2 (Air flight- kerosene)
0
100
200
300
400
500
600
700
19.8
474
23.6
566
24.4
586
20.3
487
CO2 footprint (kg)
Composite Panel Aluminium PanelStainles steel Panel Steel Panel
o Case 1: Effect of the transportation is a minor contributor to the total impacts with only >1% of the prodcut CF
o Case 2 : High impact of transportation in the air flight type with both energy and CO2 footprint.
Use phase case scenarios
03.05.2023 19
a-Dies
el-fam
ily ca
r
b-Gas
oline
-family
car
c- Elec
tric-fa
mily ca
r0
50000100000150000200000250000
Energy Consumption (MJ)
Composite Panel Aluminium PanelStainless steel Panel Steel Panel
a-Dies
el-fam
ily ca
r
b-Gas
oline
-family
car
c-Elec
tric-fa
mily ca
r0
4000
8000
12000
16000
CO2 footprint (kg)
Composite Panel Aluminium PanelStainless steel Panel Steel Panel
Further work for improvements A. Biocomposite:less CO2 emissions, lower embodied energy of materials, ease depletion of non-renewable resources and the possibility for biodegradation taking place as an end-of-life option.B. Material recyclingC. Chemical recycling methodD. Co-processing
03.05.2023
European Composites Industry Association (EuCIA ), "Composites Recycling Made Easy,"
EuCIA , 2011. 20
Conclusion• The use phase of the vehicle shows the most significant
enviromental impact emissions of the entire life cycle of the panel.
• By using composite materials, the use phase emissions from a vehicle were reduced due to lower weight/improved performance of composites.
• Implementing the recycling methods: (pyrolysis-hydrolysis-chemical recycling-biodegradation) at the end of life phase.
03.05.2023 21
Acknowledgement
Prof. Jyrki Vuorinen
Mikko Lassila, Kim Sjödahl, Eric Moussiaux
03.05.2023 22
Thank you for kind attention
03.05.2023 23