life cycle management (lcm) methodology for the auto sector

Life Cycle Management (LCM) Methodology for the Auto Sector

Life Cycle Management Methodology - Need

• Suppliers and OEM’s need common recognized process

• Need to be “Quick” for business decision making purposes


• Support Strategic Decision making – Intended to be screening methodology– Used for relative comparisons; – Not intended to generate quantitative or absolute

comparisons (i.e. green labeling)


• Used by suppliers to identify potential product life cycle Issues

• Screening methodology which may lead to more in- depth and focused LCA


Auto Sector - Life Cycle Management Screening Methodology

• Promote facilitated identification, discussion and resolution of product Environmental issues between OEM’s and supply chain

• Provides methodology to ensure Environmental impacts are not being shifted from one product phase to another (between OEM and supply chain)

• Establishes forum for development and refinement of Life Cycle / sustainability tools for the auto sector

Objective

National LCI Database

CommonManufacturing Modules

CommonRaw Material Data Modules?

QuantitativeVehicle /ProductSpecific LCA• Vehicle Specific Components •Vehicle Specific In-Use• Vehicle Specific End of Useful Life

Peer Reviewed Method / data

SP Life Cycle Screening MethodologySupplier SpecificManufacturingModels / data

Supplier SpecificProduct ScenarioModels / data

Common VehicleIn-use ; End of Useful LifeAssumptions / Model

Qualitative / Relative Component Contribution to Life cycle Impact of Hypothetical Vehicle(s)

SP Screening ResultMay Lead to Deeper DiveBy OEM / Specific Supplier

Box in Red is what we need to build

Supplier Product Engineering

Supplier Product Manufacturing

Raw Material & Energy Production

Disposal of ELV

Dismantle/Disassembly Shredding

Landfilling

Metal Recycling: -- Ferrous ~70%

Material RecoveryReUse

Spare Part SaleRecycle

De-Pollute

Metal Recycling: -- NonFerrous ~3-8%

Incinerate for Energy recoveryNon – Metal (polymer)

Material Separation

Metal Material Separation

Fluids Solids

Engine oilgearbox oildifferential oilbrake liquidsteering liquidcooling liquidfuelcooling fluid

BatteriesFiltersCatalytic ConverterTires & wheelsPowertrain (engine & transmission)Fuel TankAir BagsRadiator

End of Life Vehicle Process

In-UseVehicle Phase

Components outlined in Red are what we need to build

USE Phase Modeling Assumptions

Fuel: unleaded, no oxygenatesTotal Vehicle Miles Traveled 100,000Life expectancy: 10 yearsFuel Economy: CAFE standard for given classFuel Consumption Ratio 0.6 (i.e., weight reduction of 10% results in fuel consumptions reduction of 6%)Mass of Vehicle: 1500 kgTailpipe Emissions: EU4 2005 Emission Standards

Federal Emission Standards for vehicle classMaintenance: Consider scope of study. Include if modeling part/component that is reasonably expected to influence maintenance life cycle impacts

Vehicle In-Use Phase Screening Methodology Assumptions March 1st USCAR Meeting Result

Fluids Solids



Disposal of ELV


Landfilling




De-Pollute


Incinerate for Energy recovery

* Possible regional variances ( Europe vs. N.America vs. Japan)

End of Life Vehicle Process*

Non – Metal (polymer) Material Separation


Economic Rules of Thumb:

• Shredder value $0.06 per kg mass shredded

• ~ $0.057 per kg used to recover energy from ASR

• ~ $0.08 to $0.11 per kilogram to recycle plastics

• BMWs Suitability for Recycling:KE (%) = cost of equivalent new material + disposal

cost of dismantling + reprocessing + logistics

End of Life Rules of Thumb Options– all non metallic waste landfilled

– ~18% fluff undergoes combustion (either in blast furnace, cement kiln, or MSW incinerator)

– end of life vehicle consumes between 0.1 and 1% of the total energy requirements of the life cycle, and 80+% of CO2 emissions are associated with the use phase

– impact of car’s end of life between 1 and 5 orders of magnitude less than the total life cycle

– End of life as a % of total life cycle impact: global warming 2%, acidification 0.01%, natural resource depletion 1%, eutrophication 11%

– from Funazaki et al. JARI 2001 & 2003 ELV studies, EOL stage had the following impact indicators, with recycling rate of 78%:

• Energy 1 to 6 GJ (0.3 to 1.4% of total for impact category; 18% Production; 81% Use)

• GWP 0.6 to 3 ton CO2 (2 to 9% of total for impact category; 17% Production, )

• AP 0.3 kg SO2 (0.6% of total for impact category)

• Air Pollution 0.4 kg SO2 (0.5% of total for impact category)

• Ozone depletion 418 g-CFC11 (74% of total for impact category; 26% Use phase)

End of Life Conclusions

• Literature values available for energy and other impacts at end of life

• No available studies on contribution of ELVs to landfill emissions

• LCA software packages offer some end of life treatment values

• Developing a simple end of life model will take a lot more work – due to technical /non technical challenges and data gaps

Fluids Solids



End of Life Vehicle Process*Disposal of ELV


Landfilling




De-Pollute



* Possible regional variances ( Europe vs. N.America vs. Japan)

Non – Metal (polymer) Material Separation


Recycle

Energy Recovery• BTU value of recovered Hydrocarbon• Combustion by-products env fate/ impact • solid waste

Three eventual fates of End of useful life vehicle components Five Components of EoL Model That Must be Considered

Landfill• Env fate of chemical constituents• Env / health impact

Dismantle Shred / Separate

Japan North America

A

B C

1

5

4

3

2


Dismantle / Re-Use / Recycle Component Part List

1) Parts that must be removed by law:Fluids drainedRefrigerant (required by law cause of CFCs)Oil filters (crushed after fluid removal)BatteriesFuel TanksTires (state dependent)Hg Switches (state dependent)Pyrotechnic devicesAirbag(s) deployed

1 2

2) Parts that are Typically Removed:Re-manufactured parts (refer to VRP list)TransmissionsEnginesRadiatorsCatalytic ConvertersAl & Mg wheels (resale/sale of material)

3) Items that could be removed:

IDIS parts (for Europe)


Dismantle / Re-Use / Recycle Component Part List1 2


Shredding/Separation Component Technology Assumptions

• Metals• Most shredders pull out steel• Depending on price of Al eddy current at end of shredder• Mg, Zinc, etc are also removed with eddy current• Most shredders have pickers i. Pull out Cu, Al, etc and put into specific bins ii. Large pieces of metal & commingled metals that magnets won’t take iii. Stainless steels also removed• Technology will leave about 3% material behind• Non-metals separation assumptions

3


Additional Components Which Need to be investigated

• Material Incineration Component - Energy Recovery & Impact assumptions

• Landfill Material Component - Chemical Fate Assumptions

4

5




Disposal of ELV


Landfilling




De-Pollute


Incinerate for Energy recoveryNon – Metal (polymer)

Material Separation


Fluids Solids



End of Life Vehicle Process

In-UseVehicle Phase

• Investigate need for common Inventory / Chemical Emission – Fate / Impact Assumptions• Facilitate Relative Risk Comparisons and Use of Method as Common Auto Sector Screening tool




Disposal of ELV

Dismantle/Disassembly ShreddingLandfilling




De-Pollute



Non – Metal (polymer) Material Separation Metal Material

SeparationFluids Solids



End of Life Vehicle Process In-UseVehicle Phase

Why? What is the Value?Why? What is the Value?

• Support Auto Sector DFE & Greening of the Supply Chain activities

• Understand Possible Environmental Trade Offs of Chemical bans, substitutions, customer specifications

• Possibly influence proposed / future chemical regulation of auto sector

• Maximize Environmental Benefit of our Environmental dollars

Next Steps

• Refine Decision Tree Approach to EoL Model Components

• Finalize first draft of Dismantled Part List

• Define Shredder / Separation Technology Component AssumptionsThursday May 6th 2:00pm @ USCAR

• Investigate need / practicality of including Incineration and Landfill Component chemical fate assumptions

• Draft Overall Screening Methodology guidance

• Run test cases through screening methodology to identify additional needs

life cycle management (lcm) methodology for the auto sector

Documents

life expectancy

material recoveryreusespare

mass of vehicle

vehicle classmaintenance

product phase

oxygenatestotal vehicle

supply chain

relative comparisons