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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

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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