life cycle inventory database for glass industry

Life Cycle Inventory Databasefor Glass Industry

~ Japanese Experience ~

Tooru KudoASAHI GLASS Co., Ltd.

Flat Glass Japan/AsiaCorporate Social Responsibility Center

Environmental & Safety Group

Special Seminar“LCI/LCA in Thailand : 5-year experience under GMTAP”

5, Feb., 2008

Glass for TomorrowGlass for Tomorrow

5, Feb., 2008LCA/LCI in Thailand : 5-year experience under GMTAP2

Contents

1. Life cycle & Boundary of Flat Glass2. LCA Sample 1; for New Product3. LCA Sample 2; for New Technology4. Conclusion ~ For Planet Earth


Contents1. Life cycle & Boundary of Flat Glass

i. Raw material stage ii. Production stageiii. Fabricating stageiv. Transporting stagev. Usage stage and Discharging stage

2. LCA Sample 1; for New Product3. LCA Sample 2; for New Technology4. Conclusion ~ For Planet Earth


1. Life cycle & Boundary of Flat Glass

Air pollution

(CO2, NOx)

Water pollution

(BOD,COD)

Solid wasteetc.

Flat Glass Production

Repairing

Recycle

Discharge

Energy

Raw materials

Wateretc.

Float glass

TemperingSputteringDouble Glazing,

Input Output

Transporting

Construction/Assembling

Fabricating

UseOther Industries


1. Life cycle & Boundary of Flat Glass~ Consumption ~

Soda ash

Dolomite

Raw materials2.6 x 106 ton

Silica sand38%

11%10%

Cullet36%

SiO2

Na2CO3

CaCO3, MgCO3

Others~5%

Scrap Glass

Flat Glass Products; ~1.4 x 106 ton/year in JapanData source; FLAT GLASS MANUFACTURERS ASSOCIATION OF JAPAN


1. Life cycle & Boundary of Flat Glassi. Raw material stage ~ Mining & Refining ~LCI of Raw Material Mining & Refining Process

Data Source; “How-to LCA=「ＬＣＡ実務入門」3. Case study of LCI for Container glass

rate

Consumption ***/ton Air emissionRawore

Elect-ricity

Dieseloil

Heavyoil

NaturalGas Water CO2 SOx NOx

ton kWh ℓ ℓ kg ton kg kg kgSilica sand 38% 1.6 17.5 1.3 12.5 13 0.02 0.01

Soda ash 11% 1.8 142.5 123.3 0.9 353 1.26 0.03Dolomite 10% 1.0 11.6 0.4 2.7 0.1 15 0.05 0.05

Cullet 36% Most of cullet are treated inside glass production plant.included in production stage

kg/ton


1. Life cycle & Boundary of Flat Glassi. Raw material stage ~ Transporting ~LCI of Raw Material Transporting Process

Data Source; “How-to LCA=「ＬＣＡ実務入門」3. Case study of LCI for Container glass

Soda ash

Silica sand

Method

Truck Rail Bulkcarrier

Silica sand 433

2780

8640

Soda ash 14400Domestic* 362

Distance / km Consumption Air emissionDiesel

oilHeavy

oilCO2 SOx NOx

ℓ/ton ℓ/ton kg/ton9011 21

0.63 358.9

10523

0.22

0.380.00

0.11

0.100.02

rate

38%

11%15%

Summarize~ CO2 emission of raw material stage ~

0.16 CO2-ton/glass-ton

* Domestic; Dolomite, Limestone, Feldspar, Salt cake, Iron oxide,…


1. Life cycle & Boundary of Flat Glassii. Production stage

Soda ash

Dolomite


Silica sand38%

11%10%

Cullet36%

SiO2

Na2CO3

CaCO3, MgCO3

Others~5%

Scrap Glass

CO

Data source; FLAT GLASS MANUFACTURERS ASSOCIATION OF JAPAN (2005)

2 emission at production stage; ~1.74 x 106 CO2-ton/yearProduction amount of Flat Glass; ~1.40 x 106 ton/year

Heavy Oil75%

Electricity

21%

Gasses 4%

Fuel260 PJ

1.51 x 106 CO2-ton

Soda ash

Dolomite


11%10% Na2CO3

CaCO3, MgCO3

CO2 emission through decomposition of carbonates= 0.23 x 106 CO2-ton


1. Life cycle & Boundary of Flat Glassii. Production stageSummarize of Environmental Aspects at Production stage

Unit emission per 1 ton of glass product

CO2-ton SOx-ton NOx-ton1.24 0.003 0.005

CO2 emission of raw material stage 162 CO2-kg/glass-ton

CO2 emission of Flat Glass at the outlet of its factory= 1.4 CO2-ton/glass-ton


1. Life cycle & Boundary of Flat Glassiii. Fabricating stage

Fabricating-Cutting-Beveling-Tempering-Sputtering-Laminating-Double glazing-…

There is no disclosed dataof energy consumption.

• Main energy source is electricity.• The environmental Impact at these fabricating stage are smaller than those of production stage.

Consumption Air emissionCoal LNG Crude CO2 SOx NOx PM53 51 24 7.3x102 0.32 0.88 0.09

LCI of Double glazing process; kg/glass-ton

Data source; TOSTEM “Environmental and Social Report 2004”Presenter edited. Half of flat glass production stage


1. Life cycle & Boundary of Flat Glassiv. Transporting stage

Flat Glass Plant

500km

1000kmAssumption;•Average transporting distance;Σ（Di x Hi / Ht ) = 394km

Di; distance between prefectural capital and plantHi; new housing units construction of i-prefectureHt; total new housing units construction

•Means of transport; 10ton truck•Carry efficiency; 60%•Fuel; diesel oil•Fuel consumption; 3.5km/l

Small environmental Impactat transporting stage

CO2 emission of transporting stage= 0.05 CO2-ton/glass-ton


1. Life cycle & Boundary of Flat Glassv. Usage stage and Discharging stage

Air pollution

(CO2, NOx)

Water pollution

(BOD,COD)

Solid wasteetc.

Flat Glass Production

Repairing

Recycle

Discharge

Energy

Raw materials

Wateretc.

Float glass

TemperingSputteringDouble Glazing,

Input Output

Transporting

Construction/Assembling

Fabricating

UseOther Industries


1. Life cycle & Boundary of Flat Glassv. Usage stage and Discharging stage

LCA; Its objectives are mainly to compare some optionsabout those environmental phase.

I show some sample of LCA about Flat Glass Products.


Contents

1. Life cycle & Boundary of Flat Glass2. LCA Sample 1; for New Product

~ LCA for “Eco-Glass” ~3. LCA Sample 2; for New Technology4. Conclusion ~ For Planet Earth


2. LCA for Eco-glass ~ Explanation of products ~

• What is “Eco-glass”?– High performance double glazing unit with

Low-E coated Glass for architectural useLow-E coating;Special metallic coating layer

Insulate Solar heat effectively

Prevent to escape “Warmｔｈ” with low thermal transmittance

Summer

Winter


2. LCA for Eco-glass ~ Objectives of LCA ~

Is “Eco-glass” really effective for global warming?– Its environmental burden is big.

• Twice amount of glass• Other material ( aluminum spacer, sealing material)• Complicated producing process

– It means quality loss at each process.– It means an additional transporting process.

We need to explain for our customer its environmental advantage by LCA


2. LCA for Eco-glass ~ Boundary ~

• Compare with– Current situation; Normal double glazing or

Single pane window with aluminum sash– “Eco-glass”; Low-E coated double glazing unit

• Compared inventory– CO2 emission

• Inventory data of each material– Flat Glass;

• Raw materials & Transporting process“How-to LCA=「ＬＣＡ実務入門」 3. Case study of LCI for Container glass

• Production process for Flat Glass & Double glazing unitActual performance data of AGC group

– Other materials ( Sash, Spacer and Sealing materials )• LCA database of JEMAI


2. LCA for Eco-glass ~ Usage stage ~

How do we evaluate an environmental impact at usage stage?– based on data from Energy Conservation Effect by Insulating

Residential Windows—CO2 Emission Reduction by Using Low-E insulating double glazing (simulation with SMASHsoftware), a publication issued by the Flat Glass Manufacturers Association of Japan in March 2003.

(Source: Flat Glass Manufacturers Association of Japan website)

Ex.) *Controlled room temperature by air conditioner ;20℃ in winter, 26℃ in summer

* Season model of Tokyo; Summer; 22, June ~ 19, Sep., Winter; 2, Nov. ~ 22, Apr.

* Controlled time; 7AM ~ 23PM, ventilating every 2~3 hours


2. LCA for Eco-glass ~ House Model ~

Floor area / ㎡ 147.40ground-floor 81.15second-floor 66.25

Opening area / ㎡model 1 34.30model 2 41.44

Model 1; for cold regionModel 2; for warm region

Sample of model for single-family house

We use a model for complex housing also.


2. LCA for Eco-glass ~ Climate Model ~Compared model for each climate model

Ⅰ Low-E-FL3+A12+FL3 Plastic sashⅡ,Ⅲ FL3+A6+FL3 Aluminum sashⅣ~Ⅵ FL3 (single pane) Aluminum sash

Ⅰ~Ⅳ Low-E-FL3+A12+FL3

Ⅴ,Ⅵ Low-E-FL3+A12+FL3(heat shielding type) Ⅱ

Ⅲ

Ⅳ

Ⅴ ⅥⅢ

Ⅰ

Base

ModifiedPlastic sash

Plastic sash

N

Cold area-subfrigid zone-

Hot area-subtropic zone-

Warm area


2. LCA for Eco-glass ~ Calculation Result ~

Number ofhouses CO2-kg/single house

Single-family house 559,720 393 701

Complex housing 644,460 245 245

Amount of CO2 emission cut10

3ton/yearｘ

Ⅰ Low-E-FL3+A12+FL3 Plastic sashⅡ,Ⅲ FL3+A6+FL3 Aluminum sashⅣ~Ⅵ FL3 (single pane) Aluminum sash

Ⅰ~Ⅳ Low-E-FL3+A12+FL3Ⅴ,Ⅵ Low-E-FL3+A12+FL3

(heat shielding type)

Base

ModifiedPlastic sash

Plastic sash


2. LCA for Eco-glass ~ Calculation Result ~

Increased amount of CO2 at production stage &Integrated amount of CO2 emission cut per single house

-5

0

5

10

15

20

0 5 10 15 20 25Elapsed years

CO

2-to

n/ s

ingl

e ho

use

[Inte

grat

ed c

ut C

O2]

–[In

crea

sed

CO

2pr

oduc

ing

stag

e]

-2

-1

0

1

2

3

4

0 1 2 3 4 5

A lot of CO2 emitted at producing can get back by the energy conservation effect in 1~2 years.


Contents

1. Life cycle & Boundary of Flat Glass2. LCA Sample 1; for New Product3. LCA Sample 2; for New Technology

~ LCA for glass recycling from ELV ~4. Conclusion ~ For Planet Earth


3. LCA for glass recycling from ELV~ Background ~

ELV;= End Life of Vehicle– 4~5 million unit of vehicle

are dismantled in Japan.– ~40kg of glass/unit– In years go by, glass was

land-filled as one of shredder residue.

We needed to develop recycling method of glass from ELV by considering its environmental advantage by LCA.

Iron 64%Plastics

9%

Glass 4%

Aluminum7%

Composition of ELV


3. LCA for glass recycling from ELV~ Production stage ~

Gasses3%

Carbonates13%

Heavy oil65%

Electricity18%

COCO22 Emission

1.74x106ton/y

17%0.3x106

ton

Caused by raw materialcan decrease by using cullet

CO2 emission at production stage in Japan

Reactionheat

There is a possibility that we can decrease CO2emission by increasing cullet ratio through recycling of glass from ELV

Soda ashDolomite

Raw materials

Silica sand38%

11%10%

Cullet36%

Others~5%

Scrap Glass


3. LCA for glass recycling from ELV~ Melting Energy ~

1000

1400

1800

2200

2600

3000

0 20 40 60 80 100Cullet ratio Wt%

Mel

ting

Ener

gy M

J/G

lass

-ton

20

30

40

50

60

70

Hea

vy O

il C

onsu

mpt

ion

l/Gla

ss-to

n

Melting EnergyHeavy Oil Consumption

Cullet ratio & Melting Energy-C. Kroger et al., Glastech. Ber., 26, 202 (1953)-

:


Silicasand

Soda Dolomite

ash

Cullet

Silica sand

Soda ash

DolomiteCullet

3. LCA for glass recycling from ELV~ Target ~

Current situation

Land-fill

ELV

shredder

100

100

Target

Sorting / Washing

ELV

Dismantle of Glass

Cullet recycle

Land-fill

shredder

70

67

303

Separating Technology •Laminated glass•Black enamel


3. LCA for glass recycling from ELV~ Inventory ~

•Recycling Process•We developed and constructed a test facility.•We gathered the inventory data through recycling test.

Tomakomai

Sendai

YokohamaNagoya

Kitakyusyu

•Recovery Process for ELV cullet•ELV Dismantle trader at each prefectural capital

5 accumulation place by truckTomakomai, Sendai, Yokohama, Nagoya, Kitakyusyu

recycling plant in flat glass factory by bulk carrier near Nagoya


3. LCA for glass recycling from ELV~ Result ~

-2.0 -1.5 -1.0 -0.5 0.0 0.5 1.0 1.5

CO2 emissionReduce Increase

Current situation

Target situation

Transporting

ShreddingLand-fill

Recycle Process

Expected amount of CO2 emission cutWe can reduce raw material mining, also.

Increased part

Melting Process

Reduced part

Transporting


Contents

1. Life cycle & Boundary of Flat Glass2. LCA Sample 1; for New Product3. LCA Sample 2; for New Technology4. Conclusion ~ For Planet Earth


4. Conclusion ~ For Planet Earth

1. Glass industry use relatively large amounts of resources and energy.

Ex. ~1.2 ton-CO2 emission / Glass 1ton

2. But glass industry can propose and offer Eco-friendly products in their Life cycle.Ex. Eco-glass (Low-E coated double glazing)

3. We should develop new products and new technology for planet earth through LCA. Especially, against for global warming issue that is urgent common problem for all over the world.

4. We should explain to our customer about LCI of our products through logical LCA.


END

Thank you for your attention!


How did we gather our inventory data?

• Reporting obligation– for research of industry dynamic state

to Ministry of Economy, Trade and Industry• Reporting contents

– consumption of raw material and energy source ( Oil, Gas & Electricity )

– manufacturing quantity• Reporting path

– Industry group, Flat Glass Manufacturers Association of Japan, gathers, tallies up and reports.

⇒So, Flat Glass Manufacturers Association of Japan has already gripped its inventory data.


History of LCA -Beginning-

• AGC got a certification of ISO14001 in 1998 Feb.（next year of COP3 ）

• In that time, I worked in R&D center of AGC.• We considered;

– What kind of activity of R&D will be useful to improve Environment impact?

• We concluded;– We should evaluate an environmental impact of our

developing products & production technologyand we should contribute to a sustainable society

• We made a plan to introduce LCA concept in the evaluation process of R&D theme.


History of LCA - Applications -• LCA for Eco-Glass；1997～

– SMASH program had been investigated already at Tokyo University.– An energy saving effect of several building materials was evaluated

using by SMASH program when Ministry of land, infrastructure andtransport of Japan made “Energy Saving Guideline for Future Generation Housing”. In that time, Flat Glass Industry cooperated in this project.

– LCA for Eco-Glass takes root in society in Japan gradually. We can appeal this result of eco-friendly performance of Eco-Glass at its sales.

• LCA for Glass recycling from ELV；2001– An automotive maker assessed LCA for new technologies of

automotive industry with cooperating of several element makers. AGC cooperated in this project ( Ex. Glass Recycling from ELV ).

• Others– LCA for Cover Glass of Solar module; 2007– LCA for recycling process of laminated glass, solar module;

2002~2007


Contents1. Introduction of ASAHI GLASS Co., Ltd.2. Life cycle & Boundary of Flat Glass3. LCA Sample of Flat Glass Products4. Conclusion ~ For Planet Earth


Contents1. Introduction of ASAHI GLASS Co., Ltd.

i. Business domainii. Company of AGC Groupiii. Group Vision iv. Environmental performance

2. Life Cycle & Boundary of Flat Glass3. LCA Sample of Flat Glass Products4. Conclusion ~ For Planet Earth


Account date: Dec., 2006

Board of Meeting/Management Committee

Flat Glass Company ; \ 515 Billion

Automotive Glass Company ; \ 301 Billion

Display Company ; \ 318 Billion

Chemicals Company ; \ 308 Billion

Electronics & Energy Company ; \ 162 Billion

We are committed to finding out just how pleasant glass can make life..

Our pursuit of safety led to this sophisticated glass.

Ensuring the biggest, brightest and most beautiful images

Technology developed in glass production is at work on the frontiers of electronics.of electronics.

Our commitment to pioneering new applications is expanding the envelope for new materials and performance chemicals.Others( Ceramics, Biochemical,… ) ; \ 84 Billion

Total Sales; \ 1,621 Billion

Allianz-Arena

1. Introduction of ASAHI GLASS Co., Ltd.i. Business domain


1. Introduction of ASAHI GLASS Co., Ltd.ii. Global Evolution

North America Europe Asia Japansubsidiary 27 98 44 AGC + 54

plant 20 55 27 77sales \ billion 205 366 436 9,130

employee 6,500 16,800 16,200 14,800

・ Main production; 23 countries

since 1952

since 1963

since 1981

since 1992

since 1907


1. Introduction of ASAHI GLASS Co., Ltd.ii. Global Evolution

AGC Flat Glass (Thailand) Co.,Ltd.Samut Prakan PlantChon Buri PlantRayong Plant

AGC Automotive Thailand Co.,Ltd.Bangpakong Plant Samut Prakan Plant

AGC Electronics (Thailand) Co., Ltd.Ayuttaya

ราชอาณาจกัรไทย

AGC Chemicals (Thailand) Co., Ltd. Bangkok Samut Prakan Plant A, BRayong Plant


1. Introduction of ASAHI GLASS Co., Ltd.iii. Group Vision

OurMission

Our Shared Values

Our Objectives

Our Principles

To make the world a brighter placeInnovation & Operational Excellence

Diversity

Environment

Integrity

【革新と卓越】

【多様性】

【環境】

【誠実】

Since 2002

We, as good global citizens, will shoulder the responsibility to contribute to a sustainable society in harmony with nature.

Environment


1. Introduction of ASAHI GLASS Co., Ltd.iv. Environmental performance - GHG -

GHG: Global Greenhouse GasGHG emission of AGC Japan

Fluorinated GHG emissions

CO2 emissions

CO2/sales of Asahi Glass Japan

Mill

ion

CO

2-to

n of

GH

G

10 to

n C

O2/m

illio

n ye

n

96% reduced!

27%reduced!


1. Introduction of ASAHI GLASS Co., Ltd.iv. Environmental performance - Wastes -

Waste sent to Landfills of AGC Japan

Recycle ratio

Land

fill a

mou

nt 1

000-

ton/

year

Rec

ycle

ratio

%


Contents1. Introduction of ASAHI GLASS Co., Ltd.2. Life cycle & Boundary of Flat Glass

i. Raw material stage ii. Production stageiii. Fabricating stageiv. Transporting stagev. Usage stage and Discharging stage

3. LCA Sample of Flat Glass Products4. Conclusion ~ For Planet Earth


Contents1. Introduction of ASAHI GLASS Co., Ltd.2. Life cycle & Boundary of Flat Glass3. LCA Sample of Flat Glass Products

i. LCA for Eco-glassii. LCA for glass recycling from ELV

4. Conclusion ~ For Planet Earth


Contents1. Introduction of ASAHI GLASS Co., Ltd.2. Life cycle & Boundary of Flat Glass3. LCA Sample of Flat Glass Products4. Conclusion ~ For Planet Earth

life cycle inventory database for glass industry

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