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How to Develop LCI Database for Thai Industry:
case study refinery products
bybyMr. Puttipong PATTANAKITTIPONGMr. Puttipong PATTANAKITTIPONG
EngineerEngineerFocus Center on LCA and Focus Center on LCA and EcoProductEcoProduct Development (FC ecoDevelopment (FC eco--LCA)LCA),,
National Metal and Materials Technology Center (MTEC),National Metal and Materials Technology Center (MTEC),National Science and Technology Development Agency (NSTDA)National Science and Technology Development Agency (NSTDA)
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ContentsContents
• Introduction: Life Cycle Assessment• Life Cycle Inventory (LCI) Data• LCI Database of Thai Industry
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Product Life Cycle ThinkingProduct Life Cycle Thinking• Life cycle thinking
expands the traditional focus on manufacturing processes to incorporate various aspects associated with a product over its entire life cycle.
• The producer becomes responsible for the products from cradle to grave and has to develop products with improved performance in all phases of the product life cycle
The life cycle of a product – and closing the loop
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Road Map - ISO 14000Management
Systems
ISO 14004 (EMS)
general guidelineson principles, systems
& supportingtechniques
ISO 14001 (EMS)
specification withguidance for use
Evaluation &Auditing Tools
EnvironmentalPerformance
Evaluation (EPE)
ISO 14031 guidelines
EnvironmentalAuditing (EA)
14010 general principles
14011-1 audit procedures
14012 qualification criteriafor environmentalauditors
Product-OrientedSupport Tools
Life Cycle Assessment (LCA)14041 general principles &
practices14042 life cycle inventory analysis14043 life cycle impact assessment14044 life cycle improvement
assessment
Environmental Labelling (EL)14020 basic principles for all
environmental labelling14021 terms & definitions14022 symbols14023 testing & verification14024 guiding principles, practices
& criteria for certificationprograms
ISO/IEC Guide 64 environmental aspects of product standardsOther standards writers
Source: Thailand Environment Institute
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ISO14040 LCA DefinitionISO14040 LCA DefinitionLCA is a technique for assessing the environmental aspects and potential impacts associated with a product, process or service by:
compiling an inventory of relevant inputs and outputs of a system;
evaluating the potential environmental impacts associated with those inputs and outputs;
interpreting the results of the inventory and impact phases in relation to the objectives of the study.
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ISO 14040 ISO 14040 Life Cycle Assessment, Life Cycle Assessment, Principles Principles and frameworkand frameworkLCA Framework
นิยามและขอบเขตของการศึกษา
การวิเคราะหบญัชีขอมลู(Inventory Analysis)
การประเมินผลกระทบ(Impact Assessment)
การแปลความหมายของผลลัพธ(Interpretation)
การประยุกตโดยตรง
• การพัฒนาและ
ปรับปรุงผลิตภัณฑ
• การวางแผนกลยุทธ
• การกําหนดนโยบาย
• การตลาด
• อื่นๆ
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LCA canLCA canAssess potential environmental impacts, atboth local and global scales
Quantify environmental impacts associatedwith a product/service
Identify the key life cycle stage
Identify the most significant impacts
Identify the main contributorsBest available scientific-based tool in comparisonsbetween products/alternatives in order to identifyenvironmentally-preferred choice
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EcoDesign
Eco-Products
Process improvement(ex. Recycle process)
EMS
Env. administration(ex.Support for recycle)
Green purchasing
Env. Education
Lifestyle Review
Env. LabelEnv. Report
Self assertionComparative assertion
LCALCA
Voluntary
ImprovementMarketing
Economic & SocialAdministration
Consumption(Consumer’s mind)
Industry
Society
Applications of LCAApplications of LCA
Source: Inaba, AIST, Japan
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Basic Concept of LCA and General ProceduresBasic Concept of LCA and General Procedures
Identify significant environmental challenges Checking DataResults InterpretationResults Interpretation
Compilation in Reports Critical ReviewLCA Examination and Utilization of Results
LCA Examination and Utilization of Results
Global warming Water pollution
EutrophicationHealtheffects
AcidificationImpact AssessmentEvaluate the impact on the
natural environment
Impact AssessmentEvaluate the impact on the
natural environment
CO2SO2NOx
Total nitrogenTotal phosphorousHeavy metals
Impact on water
Impact on Air
Inventory AnalysisEstimate the environmental
impact of the product life cycle
Inventory AnalysisEstimate the environmental
impact of the product life cycle
Raw MaterialAcquisition
Trans-portation
Material Parts Assembly Products Use, RepairDis-
assembly Incineration Landfill
Recycling and Reuse
Setting up Scope of Research
Life-CycleStage
Identificationof Unit Process
Setting up Scope of Research
Life-CycleStage
Identificationof Unit Process
Recycling
Trans-portation
Source: Norihiro Itsubo
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Life Cycle InventoryLife Cycle Inventory
Materials
Electricity Fuels
Manufacturing Use Disposal
Mining
Source: INABA, AIST
Background Data
Foreground Data
Importance
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LCI Database in ThailandLCI Database in Thailand
Federation of Thai Industry Ministry of Industry(Department of Industrial Works)
Thai Environment Institute Thailand Research Fund
National Metal and MaterialsTechnology Center
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Thailand National LCI DatabaseThailand National LCI Database
Agriculture
CassavaCottonCornNatural rubberVegetable oillivestockAnimal feedSugar canerice
Recycle and Waste Management
RecycleLandfillAnaerobic digestionIncineration
Commodity chemicals
NaOHH2SO4HClCl2LimeNa2CO3Sulfur
Industrial materials
Plastics (PS, PE, PP, etc.)Non-ferrous metalsFerrous metalsAluminumFibersSynthetic rubber (SBR, BR)PaperPetrochemicals (7)
Building and Constructionmaterials
SteelGypsumCementGlassWoodTiles
Basic MaterialsBasic Materials
Energy, Utilities and Transportation
CoalPetroleumElectric powerTransportation systemWater supply (surface / ground)
InfrastructureInfrastructure
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Steering Committee
Central LCI Database
Technical Committee#1
WG6:
Construction
materials
WG4:
Ferrous/non-ferrous
WG7:Agriculture
WG5:
Transportation system
WG8:Basic chemicals
WG9:Recycle &
Waste management
Firs
t sta
geSe
cond
stag
e
(MTEC)
2007
-200
8
Technicaladvices
2006
Technical Committee#2
PTIT
WG2:RefineryProducts
Input-Output data(actual, estimate,
theory)
WG3: Petrochemical
Products
WG1: Natural Gas
Avg.data
Technical advices
Avg.data
Industrial Specific Institutions
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Search
Data Receive
Input Correction
Record
Data trans.
Registration
LCA Data-Base
InternetServer
Pass WordInput
Pass WordID
Data Input Org. Central Database User
Net Work System of LCI Database
Source: Nobuhiko Narita, Japan Environmental Management Association for Industry
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Operation ProcedureOperation Procedure
CentralDatabase(MTEC)
PTIT
•Natural gas•Refinery products•Petrochemical products
FTI and Industrial Specific
Institutions
•Construction Mat.•Basic chemicals•Etc.
Others•Transportation•Agricultural products•Electricity•Tap water
AVERAGEAVERAGEDATADATA
AVERAGEAVERAGEDATADATA
AVERAGEAVERAGEDATADATA
USERs•Member/partner•Govermental sector•Research Institute/University•Others
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LCI LCI DatabaseDatabase““RefineryRefinery ProductProduct””
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Data managementData managementcom. A
com. B
com. C
com. D
PTIT
• Develop questionnairewith MTEC
• Allocate confidential database on product
• Feed average data tocentral database
• Verify the data
Central database
• Receive average data for eachproduct
• Verify/Validate the data by crosscheck method
• Transform the average data todatabase format
• Distribute database via internetusing XML file
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Working ProcessWorking Process
Setting Up Scope
Data Gathering
Data Analysis
Verification
Validation National Database
Template Preparation
Gate to Gate
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Working ProcessWorking Process
Setting Up Scope
Data Gathering
Data Analysis
Verification
Validation National Database
Template Preparation
Gate to Gate
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Scope and BoundaryScope and Boundary• Gate to Gate
– Input: Material, External Energy, External Utility
– Output: Product, Co-product, Pollution– Period: 2005-2006
• Product list– Diesel– Gasoline– Gasohol– JET– Kerosene– LPG– Fuel Oil
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Raw material
Air emission
Product
By Product
Wastewater
Solid Waste
External FuelExternal Water
External Electricity
Scope of LCIScope of LCI
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Raw material
Air emission
Product
By Product
Wastewater
Solid Waste
External FuelExternal Water
External Electricity
Process
Scope of LCIScope of LCI
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Life cycle inventory– Data collection
• Literature information– scientific papers, public reports, LCA reports– electronic databases (part of LCA software)
• Questionnaire• Calculations
– based on mass balances• Measurements
– product-specific data
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Flow Diagram of RefineryFlow Diagram of Refinery
Source: Petroleum Institute of ThailandSource: Petroleum Institute of Thailand
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Raw Material Quantity Unit
Crude oil xxx kg
MTBE xxx kg
Ethanol xxx kg
Chemical xxx kg
Catalyst xxx kg
... xxx
Utilities Quantity Unit
Electricity (onsite) xxx MJ
Electricity (outside) xxx MJ
Steam xxx MJ
Cooling water xxx m3
Potable water xxx m3
Air xxx m3
Air Emission Quantity Unit
CO2 xxx kg
NOx xxx kg
SO2 xxx kg
TSP xxx kg
CFC xxx kg
CO xxx kg
VOCs xxx kg
Heavy Metal xxx kg
Product Quantity Unit
Diesel xxx kg
Benzin 91 xxx kg
Benzin 95 xxx kg
JET xxx kg
Kerosene xxx kg
LPG xxx kg
Asphalt xxx kg
Sulfur xxx kg
Water Emission Quantity Unit
Steam xxx kg
BOD xxx kg
COD xxx kg
Sulfide xxx kg
Oil&Grease xxx kg
SS xxx kg
TDS xxx kg
Total N xxx kg
Total P xxx kg
Heavy Metal xxx kg
….. xxx
Solid Waste Quantity Unit
Oil Sludge kg
…..
Refinery
Overall Data
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Example of Questionnaire
Input Inventory
Code Detail Quantity Unit Note
F1 Crude oil XXXXX 1000MT From unit xxxx
F_CDU Chemical xxx XXXXX Ton -
…… …… …… …… …...
Inputs
Crude Distillation Unit
F1
U_CDU
F2
F3
F4
F5
E_CDU
Code Detail Quantity Unit Note
U_CDU Electricity XXXXX 1000MWh -
U_CDU Fuel XXXXX Ton -
U_CDU Steam XXXXX ….. …..
Utilities
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Example of QuestionnaireExample of QuestionnaireOutput Inventory
Code Detail Quantity Unit Note
F2 LPG XXXXX 1000MT -
F3 TOP XXXXX 1000MT -
F4 Naphtha XXXXX 1000MT -
…… …… …… …… ……
Products
Code Detail Quantity Unit Note
EW Condensate XXXXX Ton -
EW Wastewater XXXXX m3 -
…… …… …… …… ……
Water Emission
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Example of QuestionnaireExample of QuestionnaireOutput Inventory (Conti)
Code Detail Quantity Unit Note
ES_CDU - - - -
…… …… …… …… …….
Solid waste
Code Detail Quantity Unit Note
EA_CDU NO2 XXXXX ppm -
EA_CDU NOx XXXXX ppm -
EA_CDU CO2 XXXXX ppm -
EA_CDU TSP XXXXX ppm -
EA_CDU Lead - - -
EA_CDU PM XXXXX ppm -
…… …… …… …… …….
EA_CDU SO2 XXXXX ppm -
EA_CDU CO XXXXX ppm -
Air Emission
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Working ProcessWorking ProcessSetting Up
Scope
Data Gathering
Data Analysis
Verification
Validation National Database
Template Preparation
Gate to Gate
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Data AnalysisData Analysis
• Simplify process
• Check mass balance and energy balance
• Allocation by energy density for each product in each process if possible
• Average by production share
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Simplify flow diagramSimplify flow diagram
CDU
HDTISOM
FCCU
CCR
HTUTCUBBU
HMUHCU
Treatment
Treatment
Treatment
Fuel GasLPG
MXGasoline/Gasohol
Kerosene
Diesel
Gas OilBitumen
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Verifying Verifying • Mass Balance• Energy Balance
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Allocation and AveragingAllocation and Averaging• Allocation: based on Energy Density• Averaging: based on production share
(Horizontal)
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Allocation and System Boundary ExpansionAllocation and System Boundary ExpansionAllocation
System Boundary Expansion
ProductionSystem
Primary Products X%
Energy and Emissions
Co-productsY%
DownstreamApplications
DownstreamApplications
Upstream Process
Units100%
Primary ProductsX%
Y%Co-products
Energy and Emissions
Petroleum System:
X = 60-70%, Y= 30-40%
DownstreamApplicationsUpstream
Process Units
X% Production System
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A comp. A1 A2 A3 A1 A2 A3 A1 A2 A
3 ave.
B comp. B1 B2 B3 ave. B1 B2 B3 B1 B2 B
3
C comp. C1 C2 C3 C1 C2 C3 + C
3
ave. +ave. +ave. ave.
Vertical method Horizontal method Hybrid Method
Averaging: base on production share (Horizontal)Averaging: base on production share (Horizontal)
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AcknowledgementAcknowledgement
• Prof. Dr. Atsushi Inaba, Japan• Mr. Fumio Tanaka, Japan• Assoc. Prof. Dr. Thumrongrut Mungcharoen,MTEC• Ms. Kirana Chomkumsri, MTEC• Petroleum Institute of Thailand: PTIT
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THANK YOU
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Components of LCAComponents of LCA
Goal Definition
andScoping
ImpactAssessment
ImprovemenAssessmen
Inventory
tt
Assessment
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Advantages of LCAAdvantages of LCARealistic associated environmental impacts:resource depletion, ecological and human health
Maximum possible impacts
Product-oriented environmental performanceassessment
Best available scientific-based tool in comparisonsbetween products/alternatives in order to identifyenvironmentally-preferred choice
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The Use of LCA by IndustryThe Use of LCA by Industry