1 Sustainable Coatings EC European Coatings Conference, 18-19 June 2013 Düsseldorf Life Cycle Assessment and Costing for Measuring Sustainability of Coatings Dr. Matthias Harsch, Julian Maruschke, Judith Schnaiter LCS Life Cycle Simulation GmbH, Backnang, Germany LCS Life Cycle Simulation GmbH www.lcslcs.de www.lcslcs.de
2 LCA and LCC for Measuring Sustainability Overview � Sustainability – Introduction � Challenges for Coatings � Tools – LCA and LCC � Application of LCA and LCC � Outlook LCS Life Cycle Simulation GmbH www.lcslcs.de
3 Sustainability – Introduction Characteristic Development of unsustainable Processes Intensity LCS Life Cycle Simulation GmbH Time www.lcslcs.de Excessive increase – short maximum – strong decrease
4 Sustainability – Introduction Challenges for a sustainable Future increasing dynamic climate change; energy consumption megatrends demographic scarce of change change resources resources sustainability sustainability fresh water LCS Life Cycle Simulation GmbH shortage increasing complexity www.lcslcs.de *Dynaxity = Dynamics + Complexity; Source: megatrends of sustainability, Bundesministerium für Umwelt, Berlin, 2008 Knowledge management of increasing “dynaxity*”
5 Sustainability – Introduction Viewing Angle overall view v iew into details LCS Life Cycle Simulation GmbH www.lcslcs.de Both views are mandatory to evaluate sustainability
6 Sustainability – Introduction Interaction between Interaction between Technosphere Technosphere, Ecosphere and Society , Ecosphere and Society Ecosphere Technosphere � technical development � evolution � application of technologies � renewable resources � scarcities of materials (?) � non-renewable resources Society sustainability LCS Life Cycle Simulation GmbH economy ecology social www.lcslcs.de Tools required to analyze this permanently changing interaction
7 Sustainability – Introduction Knowledge Management - Part of LCS Services production technology LCS sites strengths, weak life cycle models worldwide points, potentials bench technologies economy chmark (state-of-the-art, (state-of-the-art, limits of profit- limits of profit- innovations) ability, cost drivers ecology LCS Life Cycle Simulation GmbH work time resources, model emissions www.lcslcs.de Understand (transparency) – rearrange – evaluate – implement
8 Sustainability – Introduction Sustainability in the Coating Industry • Coatings are generally sustainable: long-term protection saves resources 1 • By corrosion and decay arises in Germany an economic loss of 3.9% (Western Europe: 3.5-4.2%) of the gross domestic product per year, equivalent to 100 billion € in 2012² • Sustainability is the driving force for new developments³ – reduction of energy consumption – raw materials, which allow a low content of volatile gases (VOC) – raw materials, which allow a low content of volatile gases (VOC) • Future properties by sustainable use of products like easy-to-clean or scratch resistance³ LCS Life Cycle Simulation GmbH www.lcslcs.de Sources:1) Deutsches Lackinstitut. 2) Deutsches Lackinstitut 2013. Nachhaltigkeit par excellence. Lack im Gespräch o.J. (114): 1. 3) European Coatings, Show 2013.
9 LCA and LCC for Measuring Sustainability Overview � Sustainability – Introduction � Challenges for Coatings � Tools – LCA and LCC � Application of LCA and LCC � Outlook LCS Life Cycle Simulation GmbH www.lcslcs.de
10 Challenges for Coatings General sustainability technical economy ecology social performance LCS Life Cycle Simulation GmbH www.lcslcs.de Fullfilment of technical performance is required
11 Challenges for Coatings Life Cycle Perspective … … … … Binders wable resources … … … … … … … Solvents … … … … … Coating End … Applic- … Non and renewa Pigments Pigments produc- produc- Use Use of of … … … ation … … tion life … … … … Fillers … … … … LCS Life Cycle Simulation GmbH … … … Additives … … … … … … www.lcslcs.de Cost, energy and material efficiency in each process step
12 Challenges for Coatings Life Cycle Modelling (LCM) – Build-up of Life Cycle into a parameterized Model Results Results Results Results LCS Life Cycle Simulation GmbH Results Results www.lcslcs.de LCM enables to look forward or backward from each point of a life cycle
13 Challenges for Coatings Life Cycle Perspective – Detail: Selection of Production Routes Products Epoxy resin Acrylic resin Polyurethane resin Epoxidharz Acrylatharz Polyurethanharz Methyldi- Hydroxy- Methyl- Polyether Polyester Bisphenol Glycidyl- Hydroxy- ethanol ethylmeth- meth- als als A methacrylat ethylacrylat als acrylat acrylat Polyol Polyol Diamin Butyl- Iso- acrylat cyanate Epichlor- Acetoncy- Dicarbon- Ethylen- Aceton Phenol Styrol hydrin anhydrin säure glykol Allyl- Calcium- Acryl- Cumol Butanol chlorid hydroxid säure Meth- Ethyl- Ethylen- Propylen- LCS Life Cycle Simulation GmbH Benzol Xylol acryl- Acrolein CO benzol oxid oxid säure Pyrolyse- Synthese- Chlor Ethylen Propylen Ammoniak Methan benzin gas Resources Steinsalz Erdöl Erdgas Sodium chloride Crude oil Natural gas www.lcslcs.de Life cycle perspective helps to find best solution
14 Challenges for Coatings Life Cycle Perspective – Detail: Material Efficiency at Application cleaning coat overspray, losses residue solids on skids 50% solids purchased purchased coat for coat for 50 on product often <20% coat application used coat 50% solvents LCS Life Cycle Simulation GmbH www.lcslcs.de cleaning coat losses residue exhaust air exhaust air spray booth drying oven
15 Challenges for Coatings Investment and Development of Operating Costs Example: medium-sized painting plant 60 potential 50 in mill. EURO 44 millions in 20 years 40 2 millions/a operating costs 30 Total costs in 20 10 LCS Life Cycle Simulation GmbH 4 millions investment 0 0 5 10 15 20 Plant operation time in years www.lcslcs.de Long plant operation time � consider the life cycle costs
16 Challenges for Coatings Procedure of Investment Decisions classical procedure plant plant functional bid placing of optimization construction specification start of solicitation an order plant document production conversion total investment optimized procedure optimized procedure technology optimization plant functional systematic plant bid simulation placing of construction specification technology start of LCS Life Cycle Simulation GmbH an order solicitation � optimized document selection production concept overview of identification promising of strengths, alternatives weaknesses and potential www.lcslcs.de Comprehensive preparation for long term investments is profitable
17 LCA and LCC for Measuring Sustainability Overview � Sustainability – Introduction � Challenges for Coatings � Tools – LCA and LCC � Application of LCA and LCC � Outlook LCS Life Cycle Simulation GmbH www.lcslcs.de
18 Tools – LCA and LCC Life Cycle Assessment (ISO Standards 14040 & 14044) production LCA framework goal/ scope definition preparation use inventory analysis analysis emissions impact to environment resources assessment LCS Life Cycle Simulation GmbH recycling renewable resources carbon cycle www.lcslcs.de Measuring ecological sustainability
19 Tools – LCA and LCC Life Cycle Costing dynamic Life Cycle Costing Disposal/ Ressources Extraction Production Use PRODUCT Recycling material cost manufacturing cost static total production cost life cycle cost different system boundaries different system boundaries CAPITAL GOODS dynamic Capital Budgeting Total Cost of Ownership LCS Life Cycle Simulation GmbH investment cost operation and maintenance cost abandonment cost Abandon- Purchase Operation static ment www.lcslcs.de Measuring economical sustainability
LCS Life Cycle Simulation GmbH www.lcslcs.de Primary Energy Demand and Material Costs Tools – LCA and LCC PE = Primary energy Co = Costs H = Hardener B = Binder Costs sts in € per kg Preis is in € pro kg 10 12 0 2 4 6 8 „Exotic“ products B/ H (PE) BM/ HÄ (PE) can have even higher values. Economy and ecology provide similar messages BM/ HÄ (Ko) B/ H (Co) Solvent (PE) Lösemittel (PE) Solvent (Co) Lösemittel (Ko) more than 700 MJ Pigmente (PE) Pigment (PE) Pigment (Co) Pigmente (Ko) Additive (PE) Additive (PE) more than 20 € Additive (Co) Additive (Ko) Filler (PE) Füllstoffe (PE) Min Max Füllstoffe (Ko) Filler (Co) 0 100 200 300 400 500 Primary ene energy in MJ per kg 20
21 LCA and LCC for Measuring Sustainability Overview � Sustainability – Introduction � Challenges for Coatings � Tools – LCA and LCC � Application of LCA and LCC � Outlook LCS Life Cycle Simulation GmbH www.lcslcs.de
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