Life-Cycle Assessment (LCA) for Spray Polyurethane Foams Session 2 - LCA Project Update.pdf ·...
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Life-Cycle Assessment (LCA) for Spray Polyurethane Foams SprayFoam 2012 Dallas InterContinental Hotel February 2, 2012 Rick Duncan Spray Polyurethane Foam Alliance George Pavlovich Bayer MaterialScience LLC Shen Tian Bayer MaterialScience LLC “The information provided herein are believed to be accurate and reliable, but are presented without guarantee or warranty of any kind, express or implied. User assumes all risk and liability for use of the information and results obtained. Statements or suggestions concerning possible use of materials and processes are made without representation or warranty that any such use is free of patent infringement, and are not recommendations to infringe any patent. The user should not assume that all safety measures are indicated herein, or that other measures may not be required. “
Transcript of Life-Cycle Assessment (LCA) for Spray Polyurethane Foams Session 2 - LCA Project Update.pdf ·...
Life-Cycle Assessment (LCA) for Spray Polyurethane Foams
SprayFoam 2012Dallas InterContinental Hotel
February 2, 2012
Rick DuncanSpray Polyurethane
Foam Alliance
George PavlovichBayer MaterialScience LLC
Shen TianBayer MaterialScience LLC
“The information provided herein are believed to be accurate and reliable, but are presented without guarantee or warranty of any kind, express or implied. User assumes all risk and liability for use of the information and results obtained. Statements or suggestions concerning possible use of materials and processes are made without representation or warranty that any such use is free of patent infringement, and are not recommendations to infringe any patent. The user should not assume that all safety measures are indicated herein, or that other measures may not be required. “
AGENDA
Definitions
Goal and Scope
Inventory Analysis
Impact Assessment
Interpretation and Value
Next Steps
Acknowledgements
What is Life‐Cycle Assessment ?Life‐Cycle Assessment (LCA) is a technique to assess environmental impacts associated with ALL stages of a product's life
raw material extraction
raw materials processing
manufacturing and blending
distribution
installation
use
disposal and recycling
packaging
What is Life‐Cycle Assessment ?LCAs prevent a narrow outlook on environmental concerns (single‐attribute evaluations) by:
• Utilizing a recognized global methodology that provides a transparent,holistic and balanced approach to product evaluation
• Compiling an inventory of all energy/material inputs and environmental releases
• Evaluating the potential impacts associated with all inputs and releases
• Interpreting the results to help customers make informed and technically sound decisions
What is Life‐Cycle Assessment ?The International Standards Organization (ISO) provides a structured process to assure fair, credible and transparent LCA results
Relevant (ISO) LCA Documents
1. ISO 14040: Environmental Management—Life Cycle Assessment—Principles and Framework, Second Edition; International Organisation forStandardisation, 2006.
2. ISO 14044: Environmental Management—Life Cycle Assessment—Requirements and Guidelines, First Edition; International Organisation forStandardisation, 2006.
What is Life‐Cycle Assessment ?Four basic stages of LCA
flow diagram from ISO 14040 Standard
Interpretation
Goal and Scope
Definition
Inventory Analysis
Impact Assessment
Goal and Scope DefinitionGoal• Enterprise/Industry: Develop environmental strategy for products and services
• Manufacturing: Create and improve sustainable manufacturing processes
• Sales and Marketing: Support environmental marketing claims, provide ‘green’ building credits for LCA/EPD credits
• Customers: Use best materials and processes and avoid single‐attribute selection
Goal and Scope DefinitionScope
• Functional Unit
• System Boundaries
• Assumptions and Limitations
• Allocation Methods
• Environmental Impact Categories
Goal and Scope DefinitionScope: Functional Unit• Defined by the primary function fulfilled by a product system• Enables equal comparison of alternative product systems• Determines the reference flow on which amounts of inputs
and outputs are calculated
• For all building insulation products, the functional unit is defined by a new Product Category Rule document[1] (2011):
1m² of insulation material with a thickness that gives a design thermal resistance RSI = 1 m²K/W and with a building service life of 60 years
Goal and Scope DefinitionScope: System BoundariesDefines what precisely what materials and processes are to be included in the LCA
Other Building Raw Materials
Other Building Raw Materials Manufacturing
Building Use Building End‐of‐LifeBuilding Installation
SPF Raw Materials
SPF Raw Materials
Manufacturing
SPF Use and Maintenance SPF DisposalSPF Installation
LCA Study Boundary
Heating / Cooling
Maintenance
Goal and Scope DefinitionScope: Assumptions and LimitationsDefines the time, technology and geographic limits of the data
• Time: Raw material and process data < 5 years old
• Technology: Three generically‐formulated SPF products
• Geography: United States
• Data: Primary data from industry sources, other raw materials from recognized sources (GaBi, NREL LCI databases)
• Cut‐off Rules: Ignore energy, materials or emissions <1% if not environmentally relevant
Goal and Scope DefinitionScope: Allocation MethodsDefines allocation of resource consumption and environmental impacts from joint production of materials used for other processes
Goal and Scope DefinitionScope: Environmental Impact CategoriesDefines environmental impacts per functional unit per Tool for the Reduction and Assessment of Chemical and Other Environmental Impacts (TRACI) 2.0 methodology, except USETox and PEI special energy flow
Impact Category Characterization Factor Description Unit
Global Warming Potential (GWP) A measure of greenhouse gas emissions, such as CO2and methane. kg CO2 equivalent
Eutrophication Potential (EP)Eutrophication covers all potential impacts of excessively high levels of macronutrients, the most important of which nitrogen (N) and phosphorus (P)..
kg Nitrogen equivalent
Acidification Potential (AP)The acidification potential is a measure of a molecule’s capacity to increase the hydrogen ion (H+) concentration in the presence of water, thus decreasing the pH value.
mol H+ equivalent
Photochemical Ozone Creation Potential (POCP)
A measure of emissions of precursors that contribute to ground level smog formation (mainly ozone O3),
kg O3 equivalent
Ozone Depletion Potential (ODP) A measure of air emissions that contribute to the depletion of the stratospheric ozone layer.
kg CFC‐11 equivalent
Additional Inventory/Impact Category
Primary Energy Demand (PED) [1]A measure of the total amount of primary energy extracted from the earth, expressed in energy demand from non‐renewable or renewable resources
MJ
Human and Eco‐Toxicity [2] Measures of carcinogenic, mutagenic and reproductive CMR impact
Case (human)
PAF*m3 (eco)[1] PED is a special inventory flow created by PEI using the concept of “primary energy”[2] Characterization factors from USETox methodology, a European based methodology developed by SETAC Life Cycle Initiative
Inventory Analysis
Other Building Raw Materials
Other Building Raw Materials Manufacturing
Building Use Building End‐of‐LifeBuilding Installation
SPF Raw Materials
SPF Raw Materials
Manufacturing
SPF Use and Maintenance SPF DisposalSPF Installation
LCA Study Boundary
Heating / Cooling
Maintenance
Inventory Analysis
Other Building Raw Materials
Other Building Raw Materials Manufacturing
Building Use Building End‐of‐LifeBuilding Installation
SPF Raw Materials
SPF Raw Materials
Manufacturing
SPF Use and Maintenance SPF DisposalSPF Installation
LCA Study Boundary
Heating / Cooling
Maintenance
Work completed by PE International• Detailed in separate report to be made available to
SPFA members• Independently reviewed by 3‐person Critical Review
Panel
Inventory Analysis
Other Building Raw Materials
Other Building Raw Materials Manufacturing
Building Use Building End‐of‐LifeBuilding Installation
SPF Raw Materials
SPF Raw Materials
Manufacturing
SPF Use and Maintenance SPF DisposalSPF Installation
LCA Study Boundary
Heating / Cooling
Maintenance
SPF Raw Materials• Includes A‐side MDI and B‐side polyols and
additives• Obtained from LCI data from GaBi and other
reputable sources
Inventory Analysis
Other Building Raw Materials
Other Building Raw Materials Manufacturing
Building Use Building End‐of‐LifeBuilding Installation
SPF Raw Materials
SPF Raw Materials
Manufacturing
SPF Use and Maintenance SPF DisposalSPF Installation
LCA Study Boundary
Heating / Cooling
Maintenance
SPF Raw Materials Manufacturing • includes transportation, blending and packaging
of raw materials by formulator• Data from six different formulators was obtained
via survey• Generic formulations provided by SPFA and CPI
Inventory Analysis
Low‐Density Open Cell SPF
Medium‐Density Closed‐
CellRoofing
Density (lb/ft3) 0.5 2.0 3.0Thermal Performance (R/inch) 3.6 6.2 6.2
B‐side Chemical SPFA CPI SPFA CPI SPFA
Polyol
Polyester ‐ ‐ 45% 36% 35%Mannich ‐ ‐ 30% 34% 45%Compatibilizer 10% 12% ‐ ‐ ‐Polyether 35% 34% ‐ ‐ ‐
Fire RetardantTCPP 25% 25% 4% 16% 8%Brominated ‐ ‐ 6% ‐ ‐
Blowing AgentReactive (H2O) 24% 20% 2% 2% <2%Physical (HFC) ‐ ‐ 9% 7% 7%
CatalystAmine 6% 8% 3.0% 4% 2%Metal ‐ ‐ <1% ‐ <1%
Surfactant Silicone <1% 1% 1.0% 1% 1%
Inventory Analysis
Other Building Raw Materials
Other Building Raw Materials Manufacturing
Building Use Building End‐of‐LifeBuilding Installation
SPF Raw Materials
SPF Raw Materials
Manufacturing
SPF Use and Maintenance SPF DisposalSPF Installation
LCA Study Boundary
Heating / Cooling
Maintenance
SPF Installation • Includes materials transportation, high‐
pressure application, PPE/consumables and factors such as trim waste and product yield
• Data from __ different SPF contractors was obtained by PEI
Inventory Analysis
Other Building Raw Materials
Other Building Raw Materials Manufacturing
Building Use Building End‐of‐LifeBuilding Installation
SPF Raw Materials
SPF Raw Materials
Manufacturing
SPF Use and Maintenance SPF DisposalSPF Installation
LCA Study Boundary
Heating / Cooling
Maintenance
SPF Disposal • Conservatively assumes all foam will go to
landfill when building is demolished
Inventory Analysis
Other Building Raw Materials
Other Building Raw Materials Manufacturing
Building Use Building End‐of‐LifeBuilding Installation
SPF Raw Materials
SPF Raw Materials
Manufacturing
SPF Use and Maintenance SPF DisposalSPF Installation
LCA Study Boundary
Heating / Cooling
Maintenance
SPF Use and Maintenance• Performed detailed energy modeling of typical new
residential home with SPF insulation to 2009 I‐code• Performed detailed energy modeling of typical existing
commercial building with SPF roofing system added (R20)• Three representative climate zones considered (MN, VA, TX)
Inventory Analysis
New Residential Home• 2434 SF with typical home• Two‐story• Wood‐frame construction• Insulated to IRC 2009 per climate zone• Air‐leakage rates from SPF vs fibrous
insulation included in model performed using EnergyGauge software
• Climate data from Minneapolis, Richmond and Houston
Existing Commercial Building• 10,000 SF post‐1980 strip‐mall building• Existing roof assembly R‐values of R4 and
R12 assumed on underside of roof deck• Additional roofing SPF added to create
R20 roof assembly per ASHRAE 90.1‐2010• Air‐leakage rates from SPF vs fibrous
insulation NOT included in model performed using EnergyPlus software
• Climate data from Minneapolis, Richmond and Houston
SPF Use-Phase Energy Modeling
Impact AssessmentCradle‐to‐Grave, minus Use‐PhaseAll results included in detailed report from PE International.
Areas of interest are PED and GWP
• Primary Energy Demand• Foam Type• Operation/Process• Raw Material Contribution
• Global Warming Potential• Foam Type• Operation/Process• Raw Material Contribution
Impact AssessmentMJ p
er fu
nctio
nal unit
0.00
20.00
40.00
60.00
80.00
100.00
120.00
140.00
160.00
Low Den 1 Low Den 2 Med Den 1 Med Den 2 Roofing
Primary Energy Demand
5. End‐of‐Life
4. Use Phase Emissions
3. Installation
2. Transportation
1. Raw Materials &Blending
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
LowDen 1
LowDen 2
MedDen 1
MedDen 2
Roofing
Polyol ‐ Polyester Polyol – Mannich Polyol – Compatibilizer
Polyol – Polyether Fire Retardant – TCPP Fire Retardant – Brominated
Blowing Agent – Reactive Blowing Agent – Physical Catalyst – Amine
Catalyst – Metal Surfactancts – Silicone PMDI
Packaging Transportation Blending
Impact Assessment
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Low Den 1
Low Den 2
Med Den 1
Med Den 2
Roofing
Polyol ‐ Polyester Polyol – Mannich Polyol – Compatibilizer
Polyol – Polyether Fire Retardant – TCPP Fire Retardant – Brominated
Blowing Agent – Reactive Blowing Agent – Physical Catalyst – Amine
Catalyst – Metal Surfactancts – Silicone PMDI
Packaging Transportation Blending
Impact Assessment
Petro‐chemical based raw materials affect Primary Energy Demand in proportion to their volumes
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
Low Den 1 Low Den 2 Med Den 1 Med Den 2 Roofing
[kg CO
2 eq
]
Global Warming Potential
5. End‐of‐Life
4. Use Phase Emissions
3. Installation
2. Transportation
1. Raw Materials & Blending
Impact Assessmentkg CO2 pe
r fun
ctional unit
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
Low Den 1 Low Den 2 Med Den 1 Med Den 2 Roofing
[kg CO
2 eq
]
Global Warming Potential
5. End‐of‐Life
4. Use Phase Emissions
3. Installation
2. Transportation
1. Raw Materials & Blending
Impact Assessmentkg CO2 pe
r fun
ctional unit HFC blowing agents have direct
impact on GWP results
Use of low‐GWP blowing agents in closed‐cell SPF will substantially lower GWP impacts
1.00E‐16
1.00E‐15
1.00E‐14
1.00E‐13
1.00E‐12
1.00E‐11
Low Den 1 Low Den 2 Med Den 1 Med Den 2
Normalized Impacts of Spray Foam
APEPGWPODPSmog
Impact Assessment
Impact AssessmentUse‐PhaseAll results included in detailed report from Sustainable Solutions.
Noticeable residential energy savings due to reduced air leakage, especially in colder climates
Moderate commercial building energy savings from additional SPF roof insulation
InterpretationYears to Recover Primary Energy Demand of SPF ‐ Commercial
Total Primary Energy Demand of
Insulation Used (MJ)
Total Years to Recover
Primary Energy Demand R4 to R20
Total Primary Energy Demand of
Insulation Used (MJ)
Total Years to Recover
Primary Energy Demand
R12 to R20Houston
803,9229.4
401,96116.7
Richmond 7.6 15.6 Minneapolis 5.1 11.9
InterpretationYears to Recover Primary Energy Demand ‐ Residential
Total Primary Energy Demand of Insulation Used (MJ)
Total Years to RecoverPrimary Energy Demand
from: No Cavity Insulation , 0.55 ACHnTo: 2009 IECC R‐values, 0.10 ACHn
MD‐SPFHouston(1) 96,792 5.6 Richmond 111,649 1.3 Minneapolis 150,772 0.9
LD‐SPFHouston(1) 55,075 3.2 Richmond 63,528 0.8
Minneapolis(2) 85,789 0.5
1. Houston home uses unvented attic, Richmond and Minneapolis homes have insulated attic floor2. Impact of additional stud depth and required vapor retarder not included for LD‐SPF in Minneapolis
InterpretationIMPORTANT NOTES ON RESULTS:
1. Results are PRELIMINARY and await critical review
2. Recovery times may be shorter; analysis does not include impacts of :• Air‐barrier Systems needed for air‐permeable insulations• Reduced HVAC system size• Reduced framing depth and structural improvements for MD‐SPF• Vapor retarder needed for LD‐SPF in cold climates
1. Product‐specific attributes will affect results• Coverage Rate• R‐value• Density• Raw Materials
Interpretation
Comparison with other Insulations…
Data for other insulations published in LCA Databases
Before comparison of environmental impacts, check:• Units• Scope of Study (cradle/end‐of‐life, cradle/gate, etc.)• Boundaries of Study• Peer‐Reviewed Process
InterpretationI‐Report Access Available to LCA Project Sponsors to evaluate• alternative materials and processes• custom/alternative formulations
Insert I‐Report screen shot
Contractor Impact
• Sales and Marketing:
• Support environmental marketing claims
• Provide LCA/EPD credits for ‘green’ building programs LEED 2012, IgCC, ASHRAE, GreenGlobes programs
• Customers:
• Select and specify best materials and processes
InterpretationProject Documents Several documents will be publically available in 2012 summarizing the key results from this project….• Detailed Technical Reports• Summary Whitepaper and Presentation• Technical Marketing Brochure• Environmental Product Declaration (EPD) • U.S. LCI Database• LCA Template (model LCI/EPD) for material suppliers
AcknowledgementsHistory• LCA project initially started in Nov 2008‐June 2009• Resumed Nov 2010 to Present
Project Volunteers• George Pavlovich and Shen Tian of Bayer MaterialScience for
technical leadership• Project Sponsor Reviewers
Funding Sources• $130k sponsorship from 17 SPFA‐member suppliers• $50k from SPFA General Budget• $5k from ACC BCMIT Program towards CRP costsmaterials
AcknowledgementsSPFA Supplier Sponsors Industry
Association Sponsors
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