life cycle assessment of incandescent, fluorescent, compact fluorescent and light emitting diode...

Procedia CIRP 15 ( 2014 ) 467 – 472

Available online at www.sciencedirect.com

2212-8271 © 2014 Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/).Selection and peer-review under responsibility of the International Scientific Committee of the 21st CIRP Conference on Life Cycle Engineering in the person of the Conference Chair Prof. Terje K. Liendoi: 10.1016/j.procir.2014.06.017

ScienceDirect

21st CIRP Conference on Life Cycle Engineering

Life Cycle Assessment of Incandescent, Fluorescent, Compact Fluorescent and Light Emitting Diode Lamps in an Indian Scenario

Kuldip Singh Sangwana*, Vikrant Bhakara, Shilpa Naika, Sylvi Nazareth Andratb aHead, Department of Mechanical Engineering, Birla Institute of Technology and Science, Pilani, Rajasthan – 333031, India

aResearch Scholar and student, Department of Mechanical Engineering, Birla Institute of Technology and Science, Pilani, Rajasthan – 333031, India bBosch India Ltd., Bangalore, India

* Corresponding author. Tel.: +91-1596-515-223 ; E-mail address:[email protected]

Abstract

One of the major challenges for the emerging economies like India is the availability of electricity for its industrial growth and household consumption. Lighting accounts for almost 20% of total electricity demand of the country. It is estimated that by 2030 power consumption by lighting will increase to 120,000 GWh/year from 55,000GWh/year consumed currently. Majority of the lighting needs (40 million light points) in India are met by highly inefficient incandescent lamps. Therefore, Central Government of India has initiated a plan to replace the incandescent lamps by compact fluorescent lamps (CFL). But a section of policy makers has pointed out the end of life environmental hazards of CFLs. This study compares the environmental impacts of four lighting systems in India – incandescent lamp, fluorescent lamp, CFL, and light emitting diode lamps – throughout the life cycle of these lighting systems. The methodology is based on the application of the international standards of life cycle assessment. The environmental impacts generated during life cycle of each lighting system have been analyzed and the robustness of the results has been validated by sensitivity analysis. It is expected that the results will provide the required quantitative assessment of different lighting systems through their life cycle to the policy makers particularly in India.

"Keywords: Life cycle assessment, Energy efficiency, Lighting technologies"

1. Introduction

India grapples with energy challenges related to energy deficiency for its emerging requirements of burgeoning middle class and industrial growth. Lighting accounts for almost 20% of total electricity demand of the country and has a significant potential for reduction of the load. It is estimated that by 2030 power consumption by lighting will increase to 120,000 GWh/year from 55,000GWh/year consumed currently. The majority of lighting needs in the country are met by highly inefficient incandescent lamps (ICL). There are 400 million lamps in Indian households, mostly ICL, consuming 70 million MWh annually [1]. Hence, the use of alternate lighting technologies (LT) is the need of the day. In a highly ambitious energy saving effort, the Bureau of Energy Efficiency (BEE), a statutory body under the Federal Power Ministry, launched a project in February 2009 to replace 400

million ICLs with CFLs across the country [2]. This innovative market transformation increased CFL sales from 20 million annually in 2003-04 to 250 million in 2009-10[1].

In May 2010 the BEE highlighted the potential for LEDs to reduce electricity demand for lighting in India in a report entitled “The Economic Case to Stimulate LED Lighting in India” [1]. The Federal government brought LED under the preferential market access policy to promote manufacturing of LED lighting products in India [3]. BEE has targeted street lighting for the trial of LED and has been providing grants to Indian municipalities to undertake pilot trials of LED street lamps. To date, 13 LED projects have been completed [1]. Despite its fair share of challenges that hinder its penetration in the price-sensitive Indian market, LED lighting has made strong inroads in the Indian lighting industry propelled by government-backing for green technologies. It is expected that the Indian LED market will grow from the current US$ 143

© 2014 Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/3.0/).Selection and peer-review under responsibility of the International Scientifi c Committee of the 21st CIRP Conference on Life Cycle Engineering in the person of the Conference Chair Prof. Terje K. Lien

468 Kuldip Singh Sangwan et al. / Procedia CIRP 15 ( 2014 ) 467 – 472

million to US$ 1279 million by 2018 [3]. However, lately some policy makers and expert are questioning the newer lighting systems particularly CFL because of their perceived end of life environmental dangers.

The objective of this study is to compare the environmental impact of the four commonly used lighting technologies in Indian markets – incandescent lamps, fluorescent lamps (FLL), compact fluorescent lamps, and light emitting diode lamps – throughout the life cycle of these lighting systems. It is expected that this study will help the policy makers as well as consumers to take informed decisions. Taking into consideration the sales of the products in each of the subcategories, the most widely sold wattage bulbs have been taken for the study, namely 60W ICL, 36W T8 FLL, 35W CFL, 5W LED. Indian electricity mix has been used to create real environmental challenges. There is lack of adequate data used in the manufacturing phase especially for the electronic components used in CFL and LED lamps. Therefore, a comprehensive inventory data has been collected for all the four lighting systems and a detailed modeling of all the electronic components has been done using the eco-invent. India is well known for the recovery of precious metals from electronic components using traditional techniques. Therefore, the disposal practices most prevalent in the country with focus on recovering precious metals from the electronic components have been used in the model. This study is expected to address the suspicious energy saving of CFL and LED lamps in the use phase, expectant environmental hazards at the end of life and the resource utilization particularly during the manufacturing phase. The study will also identify the key issues that need to be focused upon to improve the ecological performance of the lamps [4].

2. Materials and method

Life cycle assessment is a scientific quantitative evaluation technique for assessing environmental impacts and resource consumption for producing a product or for a process from the raw materials extraction to final disposal, which is the entire life cycle (from cradle to grave)[5]. LCA can be used as a technical tool to evaluate environmental consequences of a product, production process, packaging or any activity across the entire life cycle of a product or service [6]. In this paper, the LCA has been performed according to the ISO 14040 guidelines. It comprises of four stages – goal and scope definition, inventory analysis, impact assessment, and interpretation [7].

2.1. Goal and Scope

The inclusive goal of the study was to find the most environmentally efficient amongst the four lighting technologies used for domestic lighting in India. Umberto and Eco-invent database have been used to model different processes in the life cycle of these four alternative lighting technologies. A cradle to grave approach has been taken up for the study to include the manufacturing, use, and end-of-life stages of these lamps. However, within these boundary considerations, transportation of the lamps has been ignored

because for all the alternatives, the type of transportation used is same, retail as well as manufacturing locations are similar. According to the data collected through personal interviews of sales professionals, 36Watt FLL, 60 Watt ICL, 36 Watt CFL and 5Watt LED lamps are fast selling products in the respective categories. Therefore, these four lamps have been chosen for the comparison.

The alternative lamps are not perfectly equivalent in terms of the intensity of light (lumen) and lifetime as shown in Table 1. Therefore, to provide a common basis for conducting life cycle analysis, the functional unit should be defined in quantified measure of performance [8]. Thus, functional unit selected for this study is lumen–hours, as the main function of any light source is to provide light throughout its stated life. The maximum amount of lighting service (life cycle) is provided by a fluorescent lamp, 36375000 lumen-hours (Table 1), therefore, this is taken as the functional unit for this study. Since an ICL, CFL or LED lamp provide lighting service less than the functional unit value, therefore, lumen–hrs of these lamps need to be multiplied by the number of lamps needed to reach the 36375000 lumen–hours [9]. The equivalent number of lamps for the comparison providing same lumen–hrs are 2.5 CFLs, 6 LEDs and 50 incandescent lamps as shown in table 1.

Table 1 Table of important specification for the lighting system

Lam

p

Wat

tage

(W

)

Lum

ens

Life

time

( Hrs

)

Lum

en-H

ours

(x

103)

( who

le li

fe)

No.

of L

amps

FLL 36 2425 15000 36375 1

CFL 35 2400 6000 14400 2.5

LED 5 300 20000 6000 6

ICL 60 720 1000 720 50

The eco-invent v2.2 database does not have a predefined module for Indian electricity mix. The use of predefined modules may result in inappropriate results for Indian scenario, therefore, an Indian electricity mix scenario as per the Central Electricity Authority of India data [9] modeled by Bhakar et al. [10] has been used in this study.

2.2. Inventory analysis

The primary data was collected by disassembly of all the lamps to their individual components. This data was complemented by the information provided by India innovation center of a well-known multinational company. Secondary data (process specific) was obtained from literature [11]. A detailed modeling of the electronic components in the ballast of the CFL and the LED lamps have been done using the eco-invent database, which is rarely found in published studies on lighting technologies. The weights of the important


components in all the four lamps have been presented in Table 2.

Table 2 Weight (gm) of the important components in the alternative lamps

It is impossible to take each and every component of the products in life cycle assessment. All studies on LCA make some assumptions and for this study the assumptions are:

i. The amount of mercury and inert gas are very less in weight, so amount of mercury was estimated based on the data sheets provided by Philips India (0.5mg for CFL and 0.3mg for fluorescent lamps). The rest of the inert gases present (e.g. Bi, In) are ignored since they are present in extremely small quantities.

ii. CFL, ICL and FLL use adhesives to seal the glass with the Edison base and this adhesive is known to contain CaCO3 and resin. But due to its unavailability in the database, an adhesive used for sealing metals has been used in the model.

iii. The fluorescent phosphor powder present in FLL and CFL is known to contain Y, Eu oxides and Ce, Tb, Mg aluminates, however, the exact quantities of these materials were not captured. Therefore, 70% REO from bastnasite at beneficiation which was found to be closest with the fluorescent phosphor powder has been used. The mounting base with choke of FLL is not considered in the study due to its very long life.

iv. The end-of-life has been modeled taking into account appropriate methods of disposal, recycling or municipal incineration for the various components as per the common practices in India. It is important to consider disposal of electronic parts for accurate results. The electronic components from the waste have been modeled to be recycled to get precious metals, which may not be widely prevalent in developed countries. Separate treatment of glass, plastic, aluminium, PWB, steel, and copper has been considered for LED lamps. Separate treatment of glass, aluminium, lead, and copper has been done for ICL. However, direct modules has been considered for CFL and FLL from eco-invent.

2.3. Impact Assessment

For the impact assessment, the well-known Centrum voor Milieuwetenschappen (CML) methodology and Eco-indicators'99 have been used. Eco- indicator'99 is an endpoint assessment method with top-down approach, which allows

environmental load in a single score. The various damage categories under this method are ecosystem quality, human health and resources. However, CML is a midpoint assessment method and it measures the environmental impacts in fifteen different categories - acidification potential(Ap)(kgSO2-Eq), climate change(Cc) (kgCO2-Eq), eutrophication potential(Ep)(kgPO4-Eq), freshwater aquatic eco-toxicity(Faet)(kg1,4-DCB-Eq), freshwater sediment eco-toxicity(Fset)(kg1,4-DCB-Eq), human toxicity(Ht)(kg1,4-DCB-Eq), marine aquatic eco-toxicity(Maet)(kg1,4-DCB-Eq), marine sediment eco-toxicity(Mset)(kg1,4-DCB-Eq), terrestrial eco-toxicity(Tet)(kg1,4-DCB-Eq), ionizing radiation(Ir)(DALYs), land use(Lu)(m2a),maladours air(Ma)(m3air), abiotic depletion(Ad)( kg antimony-Eq), photochemical (smog)(Kg ethylene-Eq), and stratospheric O3 depletion(Od)(Kg CFC-11-Eq).

3. Results and discussion

The Umberto results of the life cycle assessment for the alternative lighting technologies are shown in table 3 and figure 1. According to the ISO standards, the reference system selection for normalization should consider the consistency throughout on the temporal and spatial scale, to get more standardized common basis for comparative studies [7].

3.1. Midpoint Assessment

The midpoint assessment results of the manufacturing (Mfg), use and end-of-life (Eol) phases are plotted in figures 1 (a - c). Figure 1(a) shows that manufacturing of CFL and LED lamps is dominant in most of the categories, whereas FLL has least impact. This significantly high values for LED lamps are due to the presence of inductor and transistor on the printed circuit board. The high values of ICL in some categories are due to high impact of glass and its moulding.

Figure 1(b) shows that the energy consumption of ICL is high whereas LED, CFL and FLL consume comparable energy. This is because the existing LED lamps have lower lumens per watt as compared to the fluorescent lamps. For example, lumens per watt for FLL are 67 whereas for LED lamp it is 60 only. In other words, the intensity per watt provided by LED lamps is lower as compared to fluorescent lamps. The energy consumption in the case of ICL is 5-6 times higher than others and the environmental impact in all categories is also highest for ICL.

Figure 1(c) shows that LED lamps have high impact in Cc, Faet, Fset, Ht, Maet, and Mset categories, whereas CFL is dominating Ep and Ir categories in the Eol phase. The ICL has high value in Lu.

3.2. End point assessment

The endpoint assessment using Ecoindicator’99 shows that the ICL has a very high contribution in human health and resources consumption. The LED lamps consume more resources and effect human health more than the CFL and FLL as shown in figure 2. The detailed endpoint assessment is given in table 4.

Material (in gm) FLL CFL LED ICL

Glass 134 43.44 4.58 30.69 Plastic 0 32 39.86 0 Aluminum 2.59 1.92 13.62 1.67 Copper Wires 0.36 0.61 1.8 0.18 PWB & Electronics 0 34.87 14.29 0

Miscellaneous(Adhesives, lead wires, tungsten filament, etc )

1.83 0.31 LED- 0.08,Ch. Steel 1.61

1.12

Packaging 22 50 39 6 Total 160.78 163.15 114.84 39.66


Table 3 Midpoint life cycle assessment results of alternative lighting technologies

Manufacturing Use End-of-life LED CFL ICL FLL LED CFL ICL FLL LED CFL ICL FLL

Air Impacts

Ap 8.41E-2 5.83E-2 2.42E-2 1.99E-3 2.17E+0 1.90E+0 1.09E+01 1.94E+0 1.23E-4 1.54E-4 1.28E-4 7.09E-5 Cc 1.36E+1 8.68E+0 5.05E+0 4.02E-1 5.62E+2 4.92E+2 2.81E+03 5.00E+2 4.94E-1 2.59E-2 1.77E-2 1.18E-2

Smog 3.93E-3 5.46E-3 4.41E-4 3.54E-5 1.87E-2 1.64E-2 9.34E-02 1.66E-2 3.23E-6 3.12E-6 3.26E-6 1.45E-6 Ir 1.23E-7 6.56E-7 1.48E-11 8.25E-8 5.73E-7 1.19E-10 2.20E-08 3.27E-6 3.27E-11 1.54E-9 5.84E-7 5.22E-11

Od 1.41E-06 6.90E-7 5.02E-7 4.39E-8 1.25E-5 1.09E-5 6.25E-05 1.11E-5 8.48E-10 2.99E-9 3.92E-9 1.38E-9 Ht 1.30E+1 1.09E+1 2.22E+0 2.44E-1 3.63E+1 3.17E+1 1.81E+02 3.23E+1 3.88E-2 4.41E-3 2.73E-2 2.07E-3 Ma 1.08E+5 2.12E+6 1.27E+2 8.45E+4 1.85E+6 1.09E+2 6.27E+04 1.06E+7 4.39E+2 5.33E+3 1.88E+6 4.92E+1

Water Impacts

Ep 1.26E-1 3.40E-2 1.04E-2 9.47E-4 9.31E-1 1.08E+0 4.65E+00 8.29E-1 3.48E-5 2.01E-4 2.62E-5 2.14E-5 Faet 2.89E+1 1.58E+1 1.69E+0 1.61E-1 1.38E+2 1.21E+2 6.90E+02 1.23E+2 1.17E+1 1.01E-2 4.65E+0 5.79E-3 Fset 5.51E+1 3.02E+1 3.53E+0 3.32E-1 2.86E+2 2.50E+2 1.43E+03 2.54E+2 2.91E+1 2.31E-2 1.16E+1 1.35E-2

Maet 1.66E+1 9.29E+0 1.01E+0 9.95E-2 8.27E+1 7.24E+1 4.13E+02 7.37E+1 4.41E+0 5.74E-3 1.71E+0 3.22E-3 Mset 2.50E+1 1.42E+1 1.67E+0 1.63E-1 1.32E+2 1.16E+2 6.60E+02 1.18E+2 9.91E+0 1.05E-2 3.90E+0 5.97E-3

Solid Impacts

Lu 6.33E-1 7.13E-1 1.21E+0 8.86E-2 1.19E+1 1.04E+1 5.97E+01 1.06E+1 2.30E-4 4.25E-4 2.42E-3 2.01E-4 Tet 2.02E-3 2.52E-3 4.59E-4 3.83E-4 1.41E-2 1.23E-2 7.06E-02 1.26E-2 8.70E-7 1.10E-6 9.40E-7 5.05E-7

Resources Ad 1.03E-1 8.08E-2 3.47E-2 2.73E-03 3.86E+0 3.38E+00 1.93E+01 3.44E+0 4.22E-5 1.75E-4 1.68E-4 8.02E-5

(a) Manufacturing

(b) Use

(c) End-of-life Figure 1 Manufacturing, use and end-of-life results of alternative lighting technologies in CML 2001

0

10

20

30

40

50

60

Ap Cc Ep Faet Fset Ht Ir Lu Maet Mset Smog Ad Od Tet

LED CFL ICL FLL

0

500

1000

1500

2000

2500

3000


LED CFL ICL FLL

0

5

10

15

20

25

30

35


LED CFL ICL FLL


Table 4 Endpoint life cycle assessment results of alternative lighting technologies

3.3. Sensitivity analysis

To check the robustness of the results, a typical sensitivity analysis is performed by changing one of the input independent variable and at the same time measuring its influence on the dependent variable(s). It measures how different values of an independent variable will impact a particular dependent variable under different conditions. Sensitivity analysis is very useful for measuring the impact of two or more than two assumed independent variables.

In this case a sensitivity analysis has been performed on the use phase of the alternative lighting technologies by changing the Indian electricity mix to Swiss electricity mix. Figure 3 shows the effect of change of electricity mix during the use phases. It clearly indicates that with the change of electricity mix, the trends are similar across the alternative lighting technologies. However, the eco-indicator’99 points have different value in the all the categories. This due to the fact that in India approx. 67.4% of electricity is generated by burning the coal and renewable energy sources contributes 1.97% of the total energy. Swiss mix the contributes of renewable energy sources is 37% and the Swiss energy is cleaner energy as compare to Indian energy

4. Conclusions

This paper compare the life cycle assessment of four alternative domestic lighting technologies – incandescent lamp, fluorescent lamp, compact fluorescent lamp, and light emitting diode lamp. The results show that the incandescent lamp are highly inefficient across all categories of life cycle assessment. The results for other three technologies are comparable. However the main conclusion of the study is that the LED lamps are not greener to fluorescent and compact fluorescent lamps as widely perceived. It is mainly because of the low lumens per watt of current LED lamps. However, it is expected that the next generation of LED lamps will have more lumens per watt as well as more lifetime hours and will

Ecosystem quality Human health Resources

acid

ifica

tion

&

eutro

phic

atio

n

Eco-

toxi

city

land

occ

upat

ion

carc

inog

enic

clim

ate

chan

ge

ioni

sing

radi

atio

n

ozon

e la

yer

depl

etio

n

resp

irato

ry e

ffect

s

foss

il fu

els

min

eral

ext

ract

ion

LE

D Manufacturing 2.81E-2 2.07E-1 3.11E-2 1.66E+0 5.10E-2 2.40E-3 2.38E-5 2.05E-1 3.64E-1 1.62E-1

Use 7.07E-1 5.52E-1 3.46E-1 1.72E+0 2.00E+0 1.27E-2 1.71E-4 4.50E+0 1.40E+1 3.68E-2 End-of-life 9.28E-5 1.58E-1 7.46E-6 7.10E-4 2.01E-3 2.88E-7 1.46E-8 3.35E-4 2.25E-4 6.89E-6

CFL

Manufacturing 1.91E-2 1.37E-1 2.27E-2 8.95E-1 3.24E-2 1.60E-3 1.36E-5 1.53E-1 2.40E-1 2.29E-1 Use 6.18E-1 4.83E-1 3.03E-1 1.51E+0 1.75E+0 1.11E-2 1.50E-4 3.94E+0 1.22E+1 3.22E-2

End-of-life 9.66E-5 9.66E-5 3.35E-5 1.08E-3 9.77E-5 2.32E-6 6.68E-8 4.56E-4 9.33E-4 1.42E-5

ICL

Manufacturing 1.14E-2 1.76E-2 3.07E-2 4.40E-2 1.86E-2 4.26E-4 1.28E-5 6.80E-2 1.68E-1 1.31E-2 Use 3.53E+0 2.76E+0 1.73E+0 8.62E+0 9.98E+0 6.35E-2 8.55E-4 2.25E+1 6.99E+1 1.84E-1

End-of-life 8.75E-5 6.86E-2 -5.30E-5 4.00E-4 6.41E-5 6.33E-7 8.82E-8 4.22E-4 9.69E-4 9.99E-6

FLL Manufacturing 1.00E-3 2.34E-3 2.72E-3 4.98E-3 1.49E-3 3.00E-5 7.43E-7 5.81E-3 1.31E-2 1.83E-3

Use 6.30E-1 4.91E-1 3.08E-1 1.54E+0 1.78E+0 1.13E-2 1.52E-4 4.01E+0 1.25E+1 3.28E-2 End-of-life 4.48E-5 5.05E-5 1.57E-5 7.10E-4 4.47E-5 1.01E-6 3.10E-8 2.11E-4 4.29E-4 6.61E-6

0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00

100.00110.00120.00

LED CFL ICL FLL

ecosystem quality human health Resources

Figure 2 End-point assessments of Alternative lighting technologies

(b) Swiss electricity mix

(a) Indian electricity mix

Figure 3 Sensitivity analysis of use phase with Indian and Swiss electricity mix

0.0010.0020.0030.0040.0050.0060.0070.0080.0090.00

100.00110.00120.00

LED CFL ICL FLL

ecosystem quality human health resources


be truly greener then the other lamps. The robustness of the results has been validated by sensitivity analysis. It is expected that the results will be useful for the policy makers and customers to take informed decision. The results may also be useful for the manufacturers to improve their products to be more efficient throughout the life cycle stages.

It is prudent to write that the present research is for Indian scenario but the eco-invent uses data in European context. The actual assessment may vary for Indian data but the objective was to compare the four alternative lighting technologies widely used in India. The end-of-life treatment of hazardous components has been taken directly from eco-invent, however, lot of research is still required for the exact treatment or disposal of hazardous components particularly from CFL and LED lamps. It would also be interesting to compare the results of this research with the results of other commercial softwares like GaBi and SimaPro.

References

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[9] Annual Report 2009–2010. Central Electricity Authority, Ministry of Power; www.cea.nic.in/sitemap.html (last accessed in June 2011)

[10] Bhakar, V., Uppala, V. V. K., Digalwar, A. K., & Sangwan, K. S. Life Cycle Assessment of Smithy Training Processes. Procedia Engineering 2013; 64:1267-1275.

[11] UK, Department for Environment, Food and Rural Affairs, London. Life Cycle Assessment of Ultra-Efficient Lamps, https://www.gov.uk/government/organisations/department-for-environment-food-rural-affairs,Published on 5th May 2009;Last accessed 29/112013, 21:15 IST.

[12] Itten,R., Frischknecht R., Stucki M., Life Cycle Inventories of Electricity Mixes and Grid, ESU-services Ltd., http://www.esu-services.ch/ourservices/, fair consulting in sustainability , Uster, July 2012, last accessed on, 02/05/2013, 23:04 IST.

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