Life Cycle Assessment and Ecodesign

1. Life Cycle Assessment and Ecodesign ARW: Life Cycle Analysis for Assessing Energy and Environmental Implications of Information Technology Budapest, Hungary September 1-3, 2003 Paulo Ferrão

2. Analysis of the evolution of the historical pattern of environmental strategies Life cycle framework- ex: electrical and electronic equipment Industrial Ecology Framework Ecodesign/DFE: a new software tool, towards the new framework Conclusions and …software demonstration Outline

3. Business-as-usual Compliance with regulation Pollution prevention Process oriented EIA, Energy audits, Envir. audits Extended product responsability Eco-efficiency Design for Environment Life Cycle Assessment Product oriented LCA Historical pattern of Environmental Strategies Time and Space Historical pattern of Environmental strategies

4. Resources Resources Life cycle thinking MSW EEE Car Components Manufacturing Assembly Use Waste Environment

5. Puts the EPR policy on place for Electrical and Electronic Equipment: The establishment, by this Directive, of producer responsibility is one of the means of encouraging the design and production of electrical and electronic equipment which take into full account and facilitate their repair,possible upgrading, reuse, disassembly and recycling. Motivation: The amount of WEEE generated in the Community is growing rapidly. The content of hazardous components in electrical and electronic equipment (EEE) is a major concern during the waste management phase and recycling of WEEE is not undertaken to a sufficient extent. DIRECTIVE 2002/96/EC on waste electrical and electronic equipment (WEEE)

6. Large household appliances Small household appliances IT and telecommunications equipment Consumer equipment Lighting equipment Electrical and electronic tools (with the exception of large-scale stationary industrial tools) Toys, leisure and sports equipment Medical devices (with the exception of all implanted and infected products) Monitoring and control instruments Automatic dispensers DIRECTIVE 2002/96/EC Categories of electrical and electronic equipment covered ANNEX IA

7. For WEEE from private households, Member States shall ensure that by the 13 August 2005: systems are set up allowing final holders and distributors to return such waste at least free of charge. when supplying a new product, distributors shall be responsible for ensuring that such waste can be returned to the distributor at least free of charge on a one-to-one basis as long as the equipment is of equivalent type and has fulfilled the same functions as the supplied equipment. without prejudice to the provisions of (a) and (b), producers are allowed to set up and operate individual and/or collective take-back systems for WEEE from private households provided that these are in line with the objectives of this Directive; DIRECTIVE 2002/96/EC on waste electrical and electronic equipment (WEEE)

8. Member States shall ensure that by 31 December 2006 at the latest a rate of separate collection of at least four kilograms on average per inhabitant per year of WEEE from private households is achieved. Regarding WEEE sent for treatment, Member States shall ensure that, by 31 December 2006, producers meet the following targets: for WEEE falling under categories 1 and 10 of Annex IA, the rate of recovery shall be increased to a minimum of 80 % by an average weight per appliance, and component, material and substance reuse and recycling shall be increased to a minimum of 75 % by an average weight per appliance; … DIRECTIVE 2002/96/EC on waste electrical and electronic equipment (WEEE)

9. Member States shall ensure that, by 13 August 2005,producers provide at least for the financing of the collection, treatment, recovery and environmentally sound disposal of WEEE from private households deposited at collection facilities, set up under Article 5(2). For products put on the market later than 13 August 2005, each producer shall be responsible for financing the operations referred to in paragraph 1 relating to the waste from his own products. The producer can choose to fulfil this obligation either individually or by joining a collective scheme. DIRECTIVE 2002/96/EC Financing in respect of WEEE from private households

10. Metals Glass Plastics Rubber Other End-of-life processing Component suppliers Manufacturer Component suppliers Raw material producers Raw material producers Dismantler Re-use Recycling Components WEEE Steel Siderurgy SR Shredder Non-ferr met.. Foundry Energy recovery Landfill

11. Sample images from a shredder

12. SR treatment methods

13. Galloo

14. Ebara

15. Recycling reduced iron metals oxygen Recycling & copper ASR (55%) Smelting melt Road Grinding Density sep. cyclone granulate construction MSW flying Gaseous Boiler ash (45%) fuel energy Exhaust gas treatment Reshment

16. Citron

17. VW Sicon

18. Others Product Life Cycle Space MSW EEE Car Components Manufacturing Assembly Use Resources Waste Physical nature of the economy Environment

19. Time and Space Historical pattern of Environmental strategies Business-as-usual Compliance with regulation Pollution prevention Process oriented EIA, Energy audits, Envir. audits Extended product responsability Eco-efficiency Design for Environment Life Cycle Assessment Product oriented LCA IndustrialEcology Creating loop closing industrial ecosystems Promoting waste exchanges Cascading energy utilization Systems Oriented Historical pattern of Environmental Strategies

20. Are there tools available to support policy makingin the new framework? Towards a physical economy

21. Others MSW EEE Car Components Manufacturing Assembly Use Resources Landfill Incineration Recycling I.E. Tech. Shredder EnvironmentalSphere Product Life Cycle Space

22. MSW Bulk- MFA MFA LCA SFA Resources Landfill Incineration I.E. Tech. Shredder EnvironmentalSphere Others Product Life Cycle Space EEE Car Components Manufacturing Assembly Use Recycling

23. TMR DMI Stocks Economy Materials Flow Analysis Air Water Air Water Foreign hidden flows Imports Exports Domestic extraction Domestic output Environmentalburdens Domestic hidden flows ENVIRONMENT * Matthews et al. (2000)

24. Adapted from Bringezu and Schütz, 2000, Total Material Requirement of the European Union, European Environment Agency, Technical report No 55. Evolution of DMI vs. GDP (1988-1997)

25. Portuguese DMI evolution

26. Portuguese DMI: Domestic/Imported • Almost all non-renewable domestic extraction is due to Rock, Clay and Clay extraction for construction • Imports: mainly fossil fuels

27. Portuguese DMI dynamics Metabolism time scale, from infraestructure to use

28. Enhance the capability of the decision making process Integrating physical and economical indicators, environmental impacts and policies with causality-effect relations Environmental indicators framework Requires appropriate Indicators Framework

29. Risk assessment costs and benefits of action/in action Effectiveness of responses Effectiveness of responses Effectiveness of responses Effectiveness of responses Eco-efficiency indicators and emissions factors Dose response indicatorsand relationships Pathways and dispersion models Indicators framework: DPSIR Responses Drivers Impact Pressures State

30. Drivers are the underlying factors that influence a variety of relevant variables very static are useful to calculate pressures indicators, to help decision-makers to plan action and to serve as basis for scenario development Pressures describe the variables that directly cause environmental burdens should be responsive due to their celerity, demonstrate the effectiveness of policy actions State show the current condition of the environment have a great inertia Used to do a first assessment of the situation, and to answer the question where do we stand? Impact describe the ultimate effects on the environment or changes of state react even slower than state indicators formalize the cause-effect relationships, are more scientific “decision models” rather then statistical indicators Response demonstrate the efforts of society, namely decision-makers to solve the problems are very fast monitor the measures taken to reduce the environmental problems, in conjunction with others indicators show the effectiveness of the measures DPSIR framework (Jesinghaus, 1999)

31. Are there tools available to support DFEin the new framework? Towards a physical economy

32. The “New Framework” requires the analysis of dismantling vs shredding Ferrous metals Reuse parts ELV Dismantler hulk Shredder Heavy SR Hazardous materials Materials for recovery/recycling Light SR Non ferrous metals separator Non ferrous metals SR Landfill Residues Materials for recovery/recycling SR separator

33. DfE Software Tool Life cycle approach The method is implemented in the EoL module of a software toolaimed at support eco efficient product design. This tool considers the product’s life cycle • Objectives: • Evaluate environmental impact through all the life cycle; • Minimize end of life costs achieving a pre specified recycling rate;

34. DfE Software Tool Structure EoL module

35. Optimization of disassembly sequence Existing methods • Exhaustive (Lambert, 2002): • Considers the product’s connection diagram. Precedence relations are established between parts; • Identifies and represents all the feasible disassemblysequences (ex: transition matrix, AND/OR graphic, Petri Net). These consist in feasible groups of parts “linked” by disassembly actions;

36. Optimization of disassembly sequence Existing methods • Exhaustive (Lambert, 2002): • Economic information is considered by attributing coststodisassembly actions and revenues to parts (reuse or recycling) • Optimum disassembly sequence is calculated using optimization methodologies such as linear programming and Petri Net optimization • May require significant amounts of computational time and dismantling information (for assessing parallel disassembly sequences) and expert user intervention

37. Optimization of disassembly sequence Existing methods • Simplified (Ramirez, 1996): • Considers the product’s bill of materials (parts and sub assemblies). Precedence relations are established for parts and sub assemblies • Revenues are attributed to parts and subassemblies (reuse, recycling, recovery or landfill). Costs are attributed to removal timesfor parts and sub assembliesAssessment of each disassembly sequence is done by evaluating the final state (set of separated parts and sub assemblies)

38. Optimization of disassembly sequence Existing methods • Simplified (Ramirez, 1996): • Optimum sequence is found by enumerating and comparing all the possible sets. For larger sets of parts a genetic algorithm based procedure is used • The results may be highly dependent on the way the user supplies information on parts, subassemblies and precedence relations, namely for complex assemblies

39. Optimization of disassembly sequence Proposed methodology • Main topics • Considers the product’s connection diagram. • Disassembly operations eliminate connections between parts. One operation may eliminate more than one connection • Precedence relations are defined for operations • The disassembly sequence is evaluated considering its final state (set of performed and non-performed operations). • In a feasible sequence, all the performed operations comply with precedence relations

40. Optimization of disassembly sequence Proposed methodology • Information for assessing economic value and recycling rate: • Operation: time (costs are proportional), parts disconnected and precedence relations • Parts: mass, material composition and reuse value.Revenuefrompart(and groups of parts)is highest EoL value(reuse, recycling, shredding and landfill) • Subassembly: higher level assembly and reuse value • EoL scenarios: recycling value, shredding value (dependent on material composition), shredding efficiencies, SR separation efficiencies and landfill cost

41. DfE Software Tool DfR module • The user supplies information on: • product structure (parts and assemblies), part materialcomposition and mass. Specific parts may be marked for removal • EoL operators costs (buildings, equipment, labor), recycled material revenues and separation efficiencies

42. Connections Precedence relations DfE Software Tool DfR module The information on operations, connections and precedence relations is introduced by completely disassembling the product

43. DfE Software Tool DfR module The Software identifies an optimum DFR strategy, (maximum dismantling profit), given a target recycling rate and the available recycling infraestructure

44. Case Study: automobile seat Product Structure

45. Case Study: automobile seat Disassembly Operations

46. Case Study: automobile seat Optimum disassembly sequence Disassembly sequence for a minimum cost achieving a recycling rate of 70%

47. Future policy directions ? Environmental strategy IndustrialEcology Productoriented Economy Monetary + Physical Indicator framework DPSIR DPSIR EIA,LCA,... + MFA, SFA,... Environmental toolbox End-of-life Environmental business Product Green dot societies + Material flows symbiosis

48. Final remarks DFE is an increasingly relevant concept, as a consequence of a broader extended product responsibility policies at an EU level The DFR concept is not limited to disassembly operations, as shredding and post shredding recycling technologies are increasingly relevant A new and innovative DFE software tool, including this broad approach was developed and used in the auto industry context Future work will be concentrated on developing a database of shredding and post-shredding recycling technologies.

49. http://in3.dem.ist.utl.pt/mscdesign/ A development integrated in a new program… M.Sc. in ENGINEERING DESIGN ….at IST, LISBON