How to Develop LCI Database for Thai Industry: case study refinery products

How to Develop LCI Database
for Thai Industry:
case study refinery products
by
Mr. Puttipong PATTANAKITTIPONG
Engineer
Focus Center on LCA and EcoProduct Development (FC eco-LCA),
National Metal and Materials Technology Center (MTEC),
National Science and Technology Development Agency (NSTDA)
1
Contents
• Introduction: Life Cycle Assessment
• Life Cycle Inventory (LCI) Data
• LCI Database of Thai Industry
2
Product Life Cycle Thinking
• Life cycle thinking
expands the traditional
focus on manufacturing
processes to
incorporate various
aspects associated with
a product over its entire
life cycle.
• The producer becomes
responsible for the
products from cradle to
grave and has to
develop products with
improved performance
in all phases of the
product life cycle
The life cycle of a product – and closing the loop
3
Road Map - ISO 14000
Evaluation &
Auditing Tools
Management
Systems
Product-Oriented
Support Tools
Environmental
Performance
Evaluation (EPE)
ISO 14004 (EMS)
Life Cycle Assessment (LCA)
ISO 14031 guidelines
Environmental
Auditing (EA)
14010 general principles
14011-1 audit procedures
14012 qualification criteria
for environmental
auditors
general guidelines
on principles, systems
& supporting
techniques
Environmental Labelling (EL)
ISO 14001 (EMS)
specification with
guidance for use
Other standards writers
Source: Thailand Environment Institute
14041 general principles &
practices
14042 life cycle inventory analysis
14043 life cycle impact assessment
14044 life cycle improvement
assessment
14020 basic principles for all
environmental labelling
14021 terms & definitions
14022 symbols
14023 testing & verification
14024 guiding principles, practices
& criteria for certification
programs
ISO/IEC Guide 64 environmental
aspects of product standards
4
ISO14040 LCA Definition
LCA is a technique for assessing the environmental
aspects and potential impacts associated with a
product, process or service by:
Œ
compiling an inventory of relevant inputs and outputs
of a system;
Œ
evaluating the potential environmental impacts
associated with those inputs and outputs;
Œ
interpreting the results of the inventory and impact
phases in relation to the objectives of the study.
5
ISO 14040 Life Cycle Assessment, Principles
and framework
LCA Framework
นิยามและขอบเขต
ของการศึกษา
การวิเคราะหบญ
ั ชีขอมูล
(Inventory Analysis)
การประเมินผลกระทบ
(Impact Assessment)
การแปลความ
หมายของผลลัพธ
(Interpretation)
การประยุกตโดยตรง
• การพัฒนาและ
ปรับปรุงผลิตภัณฑ
• การวางแผนกลยุทธ
• การกําหนดนโยบาย
• การตลาด
• อื่นๆ
6
LCA can
9 Assess potential environmental impacts, at
both local and global scales
9 Quantify environmental impacts associated
with a product/service
9 Identify the key life cycle stage
9 Identify the most significant impacts
9 Identify the main contributors
9 Best available scientific-based tool in comparisons
between products/alternatives in order to identify
environmentally-preferred choice
7
Applications of LCA
Industry
Voluntary
Improvement
EcoDesign
Eco-Products
Process improvement
(ex. Recycle process)
Marketing
Self assertion
Comparative assertion
Env. Label
Env. Report
LCA
EMS
Env. administration
(ex.Support for recycle)
Economic & Social
Administration
Env. Education
Lifestyle Review
Green purchasing
Society
Consumption
（Consumer’s mind)
8
Source: Inaba, AIST, Japan
Basic
BasicConcept
ConceptofofLCA
LCAand
andGeneral
GeneralProcedures
Procedures
Raw Material
Acquisition
Setting
Settingup
up
Scope
of
Scope of
Research
Research
Material
Transportation
Parts
Assembly
Disassembly Incineration
Products Use, Repair
Landfill
Transportation
Life-Cycle
Life-Cycle
Stage
Stage
Identification
Identification
ofofUnit
UnitProcess
Process
Recycling and Reuse
Recycling
Inventory
Analysis
Inventory
Analysis
Estimate
the environmental
Estimate the
environmental
impact
impactofofthe
theproduct
productlife
lifecycle
cycle
CO2
SO2
NOx
Impact
Assessment
Impact
Evaluate
theAssessment
impact on the
Evaluate
the impact on the
natural
naturalenvironment
environment
Total nitrogen
Total phosphorous
Heavy metals
Impact on
Air
Global
warming
Water pollution
Eutrophication
Identify significant
Results
Interpretation
Results Interpretation environmental challenges
LCA
LCAExamination
Examination
and
Utilization
and UtilizationofofResults
Results
Compilation in Reports
Health
effects
Impact on
water
Acidification
Checking Data
Critical Review
9
Source: Norihiro Itsubo
Life Cycle Inventory
Use
Manufacturing
Disposal
Importance
Foreground
Data
Materials
Mining
Electricity
Fuels
Background Data
Source: INABA,10AIST
LCI Database in Thailand
Federation of Thai Industry
Ministry of Industry
(Department of Industrial Works)
National Metal and Materials
Technology Center
Thai Environment Institute
Thailand Research Fund
11
Thailand National LCI Database
Basic Materials
Infrastructure
Energy, Utilities
and Transportation
Coal
Petroleum
Electric power
Transportation system
Water supply (surface / ground)
Recycle and Waste
Management
Recycle
Landfill
Anaerobic digestion
Incineration
Industrial materials
Agriculture
Plastics (PS, PE, PP, etc.)
Non-ferrous metals
Ferrous metals
Aluminum
Fibers
Synthetic rubber (SBR, BR)
Paper
Petrochemicals (7)
Commodity
chemicals
NaOH
H2SO4
HCl
Cl2
Lime
Na2CO3
Sulfur
Cassava
Cotton
Corn
Natural rubber
Vegetable oil
livestock
Animal feed
Sugar cane
rice
Building and Construction
materials
Steel
Gypsum
Cement
Glass
Wood
Tiles
12
Steering Committee
Avg.data
Central LCIAvg.data
Database
Technical
Committee#1
Technical
advices
2006
First stage
(MTEC)
Input-Output data
(actual, estimate,
theory)
WG1:
Natural Gas
PTIT
WG2:
Refinery
Products
WG3:
Petrochemical
Products
Technical
Committee#2
Industrial Specific Institutions
2007- 2008
Second stage
Technical advices
WG4:
WG5:
WG6:
Ferrous/non
-ferrous
Transportation
system
Construction
materials
WG7:
Agriculture
WG8:
Basic chemicals
WG9:
Recycle &
Waste
management
13
Net Work System of LCI Database
Data Input Org.
Central Database
Registration
Input
Correction
User
Pass Word
Input
Search
Record
LCA Data-Base
Pass Word
ID
Data Receive
Data trans.
Internet
Server
Source: Nobuhiko Narita, Japan Environmental Management Association for Industry
14
PTIT
•Natural gas
•Refinery products
•Petrochemical
products
FTI and
Industrial
Specific
Institutions
•Construction Mat.
•Basic chemicals
•Etc.
Operation Procedure
USERs
AVERAGE
DATA
AVERAGE
DATA
Central
Database
(MTEC)
•Member/partner
•Govermental sector
•Research Institute/
University
•Others
AVERAGE
DATA
Others
•Transportation
•Agricultural products
•Electricity
•Tap water
15
LCI Database
“Refinery Product”
16
Data management
com. A
com. B
PTIT
com. C
Central
database
com. D
• Develop questionnaire
with MTEC
• Allocate confidential data
base on product
• Feed average data to
central database
• Verify the data
• Receive average data for each
product
• Verify/Validate the data by cross
check method
• Transform the average data to
database format
• Distribute database via internet
using XML file
17
Working Process
Setting Up
Scope
Template
Preparation
Gate to Gate
Data Gathering
Data Analysis
Verification
Validation
National Database
18
Working Process
Setting Up
Scope
Template
Preparation
Gate to Gate
Data Gathering
Data Analysis
Verification
Validation
National Database
19
Scope and Boundary
• Gate to Gate
– Input: Material, External Energy, External
Utility
– Output: Product, Co-product, Pollution
– Period: 2005-2006
• Product list
–
–
–
–
–
–
–
Diesel
Gasoline
Gasohol
JET
Kerosene
LPG
Fuel Oil
20
Scope of LCI
Air emission
Raw material
External Fuel
External Water
External Electricity
Product
By Product
Wastewater
Solid Waste
21
Scope of LCI
Air emission
Product
Raw material
External Fuel
External Water
External Electricity
By Product
Process
Wastewater
Solid Waste
22
Life cycle inventory
– Data collection
• Literature information
– scientific papers, public reports, LCA reports
– electronic databases (part of LCA software)
• Questionnaire
• Calculations
– based on mass balances
• Measurements
– product-specific data
23
Flow Diagram of Refinery
24
Source: Petroleum Institute of Thailand
Air Emission
Overall Data
Raw Material
Quantity
Unit
Crude oil
xxx
kg
MTBE
xxx
kg
Ethanol
xxx
kg
Chemical
xxx
kg
Catalyst
xxx
kg
...
xxx
Utilities
Quantity
Quantity
Unit
CO2
xxx
kg
NOx
xxx
kg
SO2
xxx
kg
TSP
xxx
kg
CFC
xxx
kg
CO
xxx
kg
Diesel
xxx
kg
VOCs
xxx
kg
Benzin 91
xxx
kg
Heavy Metal
xxx
kg
Benzin 95
xxx
kg
JET
xxx
kg
Kerosene
xxx
kg
LPG
xxx
kg
Asphalt
xxx
kg
Sulfur
xxx
kg
Quantity
Water Emission
Refinery
Unit
Product
Unit
Quantity
Unit
Steam
xxx
kg
Electricity (onsite)
xxx
MJ
BOD
xxx
kg
Electricity (outside)
xxx
MJ
COD
xxx
kg
Steam
xxx
MJ
Sulfide
xxx
kg
Cooling water
xxx
m3
Oil&Grease
xxx
kg
Potable water
xxx
m3
SS
xxx
kg
Air
xxx
m3
TDS
xxx
kg
Total N
xxx
kg
Total P
xxx
kg
Heavy Metal
xxx
kg
…..
xxx
Solid Waste
Oil Sludge
…..
Quantity
Unit
kg
25
Example of Questionnaire
F2
F3
F1
U_CDU
F4
Crude
Distillation Unit
F5
Input Inventory
E_CDU
Inputs
Code
Detail
Quantity
Unit
Note
F1
Crude oil
XXXXX
1000MT
From unit xxxx
F_CDU
Chemical xxx
XXXXX
Ton
-
……
……
……
……
…...
Utilities
Code
Detail
Quantity
Unit
Note
U_CDU
Electricity
XXXXX
1000MWh
-
U_CDU
Fuel
XXXXX
Ton
-
U_CDU
Steam
XXXXX
…..
…..
26
Example of Questionnaire
Output Inventory
Products
Code
Detail
Quantity
Unit
Note
F2
LPG
XXXXX
1000MT
-
F3
TOP
XXXXX
1000MT
-
F4
Naphtha
XXXXX
1000MT
-
……
……
……
……
……
Quantity
Unit
Note
-
Water Emission
Code
Detail
EW
Condensate
XXXXX
Ton
EW
Wastewater
XXXXX
m
……
……
……
……
3
……
27
Example of Questionnaire
Output Inventory (Conti)
Air Emission
Code
Detail
Quantity
Unit
Note
EA_CDU
NO2
XXXXX
ppm
-
EA_CDU
NOx
XXXXX
ppm
-
EA_CDU
SO2
XXXXX
ppm
-
EA_CDU
CO
XXXXX
ppm
-
EA_CDU
CO2
XXXXX
ppm
-
EA_CDU
TSP
XXXXX
ppm
-
EA_CDU
Lead
-
-
-
EA_CDU
PM
XXXXX
ppm
-
……
……
……
…….
Detail
Quantity
Unit
Note
-
-
-
……
……
…….
……
Solid waste
Code
ES_CDU
……
……
28
Working Process
Setting Up
Scope
Template
Preparation
Gate to Gate
Data Gathering
Data Analysis
Verification
Validation
National Database
29
Data Analysis
• Simplify process
• Check mass balance and energy balance
• Allocation by energy density for each product
in each process if possible
• Average by production share
30
Simplify flow diagram
HDT
ISOM
Treatment
MX
Gasoline/
Gasohol
CCR
CDU
Treatment
Kerosene
Treatment
FCCU
HTU
TCU
BBU
Fuel Gas
LPG
Diesel
HMU
HCU
Gas Oil
31
Bitumen
Verifying
• Mass Balance
• Energy Balance
32
Allocation and Averaging
• Allocation: based on Energy Density
• Averaging: based on production share
(Horizontal)
33
Allocation and System Boundary Expansion
Allocation
Upstream
Process
Units
X%
X%
Production
System
Primary Products
Downstream
Applications
Energy and
Emissions
Y%
Co-products
Petroleum System:
X = 60-70%, Y= 30-40%
System Boundary Expansion
Upstream
Process
Units
100%
X%
Production
System
Primary Products
Downstream
Applications
Energy and
Emissions
Y%
Co-products
Downstream
Applications
34
Averaging: base on production share (Horizontal)
Ａ comp.
Ａ1
Ａ2
Ａ3
Ａ1
A2
Ａ3
Ａ1
Ａ2
Ａ
3
ave.
Ｂ comp.
B1
Ｂ2
Ｂ3
ave.
Ｂ1
Ｂ2
Ｂ3
Ｃ1
Ｃ2
Ｃ3
Ｂ1
Ｂ2
Ｂ
3
Ｃ comp.
Ｃ1
Ｃ2
Ｃ3
＋
Ｃ
3
ave. ＋ave. ＋ave.
Vertical method
Horizontal method
ave.
Hybrid Method
35
Acknowledgement
•
•
•
•
•
Prof. Dr. Atsushi Inaba, Japan
Mr. Fumio Tanaka, Japan
Assoc. Prof. Dr. Thumrongrut Mungcharoen,MTEC
Ms. Kirana Chomkumsri, MTEC
Petroleum Institute of Thailand: PTIT
36
THANK YOU
37
Components of LCA
Impact
Assessment
Goal
Definition
and
Scoping
Improvemen t
Assessment
Inventory
Assessment
38
Advantages of LCA
9 Realistic associated environmental impacts:
resource depletion, ecological and human health
9 Maximum possible impacts
9 Product-oriented environmental performance
assessment
9 Best available scientific-based tool in comparisons
between products/alternatives in order to identify
environmentally-preferred choice
39
The Use of LCA by Industry
40