environmental indicators for paper/board value chains...
TRANSCRIPT
128.4.2016
Environmental indicators for paper/board value chains based on paper for recycling –
Challenges of allocation methods
Catharina Hohenthal – VTT (Finland)Jorge León – ITENE (Spain)
Workshop on 19th of April 2016, Darmstadt, Germany
228.4.2016
Co-funded by the European Union
Index
1. Life Cycle Assessment – Value Chain2. Resource efficiency indicators3. Reffibre cases testing indicators4. Allocation Methods 5. Testing the methods6. Conclusions
328.4.2016
Co-funded by the European Union
Sustainability objectives and challenges
The value chain level impacts of energy and material savings due to optimized use of recycled fiber
Identifying indicators suitable for resource-efficiency in pulp and paperindustry, taking into account the recycling loop Allocation of the burdens between different life cycles
(background processes, co-product allocation, number or reusecycles for fibre recycling, etc.)
To develop tools to be used for product design taking into accountenvironmental and economic impacts throughout the value chain Converting the LCA and economic impacts to exploitable data for
monitoring the processes
428.4.2016
Co-funded by the European Union
Paper Value Chain
Deinking
Papermaking Converting use collection
Waste sorting
Sorting of paper
NEW processes
Incineration
Fresh fiber
Recycled fiber
Fiber from other value chains
Landfill
Pulping (mech./chem.)
WWT
E.g. EtOH
ELE Water
Ash
Reffibre process in focus
Outside focus
528.4.2016
Co-funded by the European UnionProcess models
The process models have to describe the modification of the materials by the process but also the effects of the process on the environment
628.4.2016
Life-cycle thinking should be the basis of the sustainability indicators
LCA is based on inventory
Inventory is based on product value chain
Value chain includes e.g. energy, chemical, raw material useand emissions in a transparent way
PROCESS
Life Cycle Assessment – LCA
728.4.2016
Co-funded by the European Union
CalculationsWhat kind of data is needed? Where to find it?
Data sources: • Process data measured by researchers• Data from manufacturer• Database data• Literature
The resource efficiency indicators are calculated by using LCA methodology Calculations made with SULCA and Simapro LCA softwares Data for the core processes were collected from the industrial partners in order
to calculate the reference scenarios The background process data was taken from VTT EcoData or EcoInvent data The recycled fiber and its processing was modelled using allocation rules
828.4.2016
Co-funded by the European Union
Indicators describing performance
ENVIRONMENTAL INDICATORS (examples)
Greenhouse gas emissions (CO2eq) Total amount of energy required (CED) Amount of renewable materials, biobased Water use, (H2Oeq) Eutrophication potential (P eq)
ECONOMIC INDICATORS (examples)
Utilization rate % Changes in cost % Change in revenue %
Different data sources!
928.4.2016
Co-funded by the European Union
Reffibre cases and how indicators describe changes
Utzenstorf cases Holmen cases Vrancart cases
1028.4.2016
Material efficiencyCase Utzenstorf
Material efficiency is increased in all cases but “increased rejects”, where the amount of waste is increased
Material efficiency is highest for “WPC ash”, where 100% of the ash fraction is utilised, and largest amount of useful products are produced (paper + WPC)
Pyrolysis case shows increased material efficiency due to decreased waste (sludge) and increased products (paper + minerals)
Totalweight of useful products
Totalweigthof useful products waste
(Sheldon et al. 2015)
1128.4.2016
Water scarcity footprint (Pfister 2009)Case Utzenstorf
Quantitative use of water throughout the product chain was assessed, taking into account:
1. Volume of consumed water 2. Location of the water use
Paper mill and energy production: Swiss water scarcity index
Rest of the product chain (chemicals, fuels): average European water scarcity index
“Less rejects”: increased electricity use at DIP plant slightly impacts the WF “Increased rejects”: increased used of
chemicals and PfR at DIP plant and impacts the WF
1228.4.2016
Co-funded by the European Union
Climate impact case Holmen
When the disposal of sludge is avoided the CO2 eq. decreases with 22%
The sludge is used to produce WPC or pyrolysis oil which both are sustainable compared to Possible references e.g. PP products
polypropyleneinjection moulding
WPC injectionmoulding
polypropyleneprofile extrusion
WPC profileextrusion
Polypropyleneproduction
WPC productionfrom sludge
baseline sludge to Pyrolysis
Pyrolysis of sludge
electricity compensation
Disposal of sludge
Transport
Fuel production and powergenerationPapermaking chemicals
Papermachine
Deinking chemicals
Deinking plant
Waste paper collection
The benefit of producing pyrolysis oil and minerals via the pyrolysis process is not taken into account here
1328.4.2016
Co-funded by the European Union
Water scarcity footprint (Pfister 2009)Case Holmen
Baseline Reffibre cases
electricity compensation
Deinking chemicals
Disposal of sludge
Fuel production and powergenerationDeinking plant +PapermachinePapermaking chemicals
Transport
Waste paper collection
WPC injectionmoulding
WPC profileextrusion
Polypropylene
PolypropyleneproductionWPC production fromsludge
1428.4.2016
Co-funded by the European Union
Case Holmen - Economic indicators
Injection molding Profile extrusionVariable cost indicator Icv= 137 % 121 %
Revenue indicator Ip= 98 % 98 %Profitability indicator *) IV= 35 % 61 %Achievable savings **) ISAV= 8.9 % 20 %
Red font = negative effectGreen font = positive effect
*) Fixed costs not included. **) At annual level, takes also into account fixed operation costs EXCEPT investments
Sludge‐WPC
1528.4.2016
Co-funded by the European Union
Results- Comparison side by side
Investment estimations are included for WPC processes
1628.4.2016
Co-funded by the European Union
Vrancart – Environmental Assessment
2,04%
4,94%
2,78%
4,21%
0%
1%
2%
3%
4%
5%
6%
IPCC GWP 100a Freshwatereutrophication
Fossil depletion Total CED(renewable and non
renewable)
% Reduction (Reffibre & Baseline scenarios) Fibre Flow method
2,31%
4,96%
3,27%
4,45%
0%
1%
2%
3%
4%
5%
6%
IPCC GWP 100a Freshwatereutrophication
Fossil depletion Total CED(renewable and non
renewable)
% Reduction (Reffibre & Baseline scenarios) ISO 14067 method
The test case for packaging paper production in Vrancart aims at describingthe potential improvements in the packaging paper production according tothe Best Available Technologies (BAT).
1728.4.2016
Co-funded by the European Union
Vrancart – Economic Assessment
Indicator % change comparing Reffibre & Baseline scenarios
Sum of variable costs 4.5%
Revenues 10.3%
Profit (variable) 15.3%
Savings: Profit (operation) 16.6%
BAU Unit
Affordable investment 29 M-€
Estimations: • Cost of capital 5%• Payback period 14 years• Resulting annuity factor 10
Fixed operations costs estimations: • All: 10% share of variable operation costs• Labour: 60% share of fixed operation costs• Overheads: 35% share of fixed operation costs• Maintenance: 5% share of fixed operation costs
1828.4.2016
Co-funded by the European Union
Conclusion on indicators
As can be seen the indicators selected show differences in environmental and economic impacts of the changes made at the case mills. The Material efficiency indicator is very easy and informative
when calculating benefits from turning waste into side products CO2 eq. and H2Oeq. needs to be calculated by system
expansion and avoided emissions since there are multiple products as functional units The indicators chosen are good for the purpose
1928.4.2016
Co-funded by the European Union
Allocation methods
2028.4.2016
Co-funded by the European Union
How to treat recycling in LCA studies
Reuse and recycling may imply that:
Inherent properties of materials in subsequent use are changed
Inputs & Outputs associated with processes for extraction & processing of raw materials final disposal of products
are to be shared by more than one product system
2128.4.2016
Co-funded by the European Union
How to treat recycling in LCA studies
Open-loop allocation:
Procedures according to ISO/TS 14067:
The material is recycled into otherproduct systems
The material undergoes a changeto its inherent properties e.g. different length of
recycled fibres: REFFIBRE
2228.4.2016
Co-funded by the European Union
How to treat recycling in LCA studies
Basis for allocation “A” (according to ISO/TS 14067)
1. Physical properties (e.g. mass)
2. Economic value: market value for the recycled & primary material
3. Number of subsequent uses of the recycled material
MFA (Mean Fibre Age)
MNU (Mean Number of Material Uses)
MFA+MNU-1: Mean number of product cycles the fibres of a given
paper product will undergo during their life
Fibre flow modelling
2328.4.2016
Co-funded by the European Union
Allocation methods in REFFIBRE
2 approaches for allocation are tested for REFFIBRE:
a) Allocation method combining ISO 14067 and the Medium Fibre Age (MFA) and Medium Number of Uses (MNU)
b) New approach based on results from the fibre flow model developed in task 1.4.
2428.4.2016
Co-funded by the European Union
Method based on ISO/TS 14067
ET = Ev * Ai * C + Epp * C + EV * (1 – C) + EPM + EEoL – R * Ao * Ev
EV = Impact tied to extracting or producing all the raw material needed for the product, from natural resources
EEoL = Impact tied to end-of-life operations (being part of the product system which delivers recycled material)
Ai = Allocation factor of the recycled material which enters the product system =
(MNU) / (MFA + MNU – 1)
EPP = Impact tied to pre-processing of the recycled material in order to fulfil the quality requirements of the substituted primary material
Ao = Allocation factor of the recycled material which leaves the product system =
(MNU – 1) / (MFA + MNU – 1)
R = recycling rate ; ∗ ∗ = recycling credit
C = Recycling content of the
product
Epm = Paper making process
2528.4.2016
Co-funded by the European Union
Method based on fibre flow model
1 ∙ 2 ∙
U: Paper for Recycling utilisation rate of the product
EW: Impact tied to waste management
Allocation factor for virgin fibre usage Allocation factor for recycled fibre usage =
= Allocation factor for not recycled paper products / rejects going directly into waste =
= Allocation factor for products being recycled (and going later into waste) =
R: Recycling rate of the product ERec: Impact tied to recycling
2628.4.2016
Testing allocation formulas – Holmen case study
-56 -56 -56
-388
572
136
501
501
501
445
445
445
244
244
268
-1000
-500
0
500
1000
1500
2000
cut-off, noallocation
ISO14067 fibre flowmodel
EoL
paper making
processing ofrecycled material
burden withrecycled
recycling credits
sold electricity
Cut-off does not include allocation: No burden for incoming recycled
material No credits from end of life recycling
For carbon footprint: ISO14067 approach: +15% more
emissions than cut-off Fibre flow model approach: +13%
more emissions than cut-off.
2728.4.2016
Co-funded by the European Union
2,31%
4,96%
3,27%
4,45%
2,04%
4,94%
2,78%
4,21%
0%
1%
2%
3%
4%
5%
6%
IPCC GWP 100a Freshwater eutrophication Fossil depletion Total CED (renewable and nonrenewable)
Comprasion of % of reduction in both methods
% reduction ISO 14067 % reduction Fibre flow model
Testing allocation methods - Vrancart
2828.4.2016
Testing how the methods work when C/U changes Formulas leads to different emissions with different recycled material contents How emissions evolve when C increases depends on:
Allocation factors (MNUs and MFAs): debits from the previous life cycles & credits from the future life cycles (recycling credits)
Emissions (Ev, Epp, Eeol, Erec, Ew etc.): especially changes in Ev have a clear impact on whether emissions decrease or increase when C changes
2928.4.2016
Co-funded by the European Union
Conclusions about allocation
Both approaches for allocation are used for Reffibre cases in Holmen,Utzenstorf and Vrancart to test how formulas work in ”real life”Paper and board value chains have been tested
When using allocation methods the main challenge is to find the right valuesto perform the calculations with the formula The results depend on the values used for recycling rate, number of uses, etc.
The use of recycling rate, number of uses, etc. have to be clearly definedand understood because the use of these affect the results significantlyThese need to be added to e.g. Product Category Rules so that the
calculations can be made as uniformly as possible Next steps: introduction of these guidelines for industry on EU level
(standards, Product Category Rules - PCR)
3028.4.2016
Co-funded by the European Union
Conclusions
Life cycle assessment is used as a methodology to take intoaccount the impacts along the whole value chain There is a need to have an easy tool for companies to integrate
environmental issues REFFIBRE project is helping by
Modelling the fiber flows and to get the average number ofuses for the different paper grades Selecting the most suitable allocation methods needed to carry
out LCA calculations Integrating the modelling in a common tool
3128.4.2016
Co-funded by the European Union
Acknowledgement
The research leading to these results has received funding from the European Community's Seventh Framework Programme under grant agreement n° 604187.
Thanks for your attention