firm BEGHELLI
Paolo Neri∗a, Patrizia Buttola, Gabriele Daniellid, Romano Pareschic, Giovanni Tanib
a
Italian National Agency for New Technologies, Energy and Environment, Bolognab
Department of Mechanics and Industrial Technology of Florence University
c
Technical Office of the firm BEGHELLI, Bologna
d
Department of Mechanical Constructions Engineering of Bologna University
ABSTRACT
This study was performed jointly by ENEA (Italian National Agency for New Technologies, Energy and Environment),Bologna and Florence Universities and the firm BEGHELLI1. The system function to be studied is the lighting of aroom where a blackout has occurred. The functional unit is an emergency lamp manufactured by BEGHELLI, providedby a fluorescent tube and an accumulator battery with lead elements. The lamp life lasts 10 years. LCA is obtained byusing the SimaPro 3.1 code and two methods: Eco indicator 95 with the normalisation weight ascribed to 10 years and anew method obtained by enclosing into the Eco – indicator 95 method some new damage categories such as some rawmaterial depletion, solid and energy.
The results show that the accumulator battery, the structure of the lamp and the electronic board are the componentswith greater environmental damage and the electrical energy for use produces 31% of total damage calculated by theEco - indicator method. The most important categories of damage produced by accumulator battery are acidification dueto material production and heavy metals due to disposal treatment of lead, and the ones produced by electronic card areacidification and winter smog due to copper production.
To reduce the damage of emergency lamp some new solutions have been proposed.Finally the characteristics to obtain emergency lamp Ecolabel have been proposed.
Keywords: Life Cycle Assessment, Emergency lamp, Ecodesign, Eco – indicator, Ecolabel, Electronic Card
1. DEFINITION OF AIMS AND BOUNDARIES OF THE STUDY.
The goal of the study is the evaluation of the environmental damage due to manufacturing, use and end of life of theemergency lamp produced by the firm BEGHELLI and the proposal of a new design solution to reducing theenvironmental damage.
The system function to studying is the emergency lighting of a room in which the output of electric energy ceasessuddenly. The emergency lighting can be used for reserve and for safety. The function that we study is the safety of thepeople.
The functional unit is a lamp of only emergency that by the Italian law 626/94 must be used in all the public rooms.The lamp emits a luminous flux of 350 lm by means of a fluorescent tube and an accumulator battery with leadelements and can be used for 10 years.
The system to studying is the emergency lamp.
The system boundaries include raw material extraction and lamp end of life.
LCA is obtained by using the SimaPro 3.1 code2 and two methods: Eco indicator 95 with the normalisation weightascribed to 10 years and a new method obtained by enclosing into the Eco – indicator 95 method some new damagecategories such as some raw material depletion, solid and energy.
In the LCA study the processes to producing some electronic components (electrolytic condenser, transistor,microprocessor, diode) have been simplified.
We have assumed that during the manufacturing a quantity of scraps is produced equal to the 2% of the weight of thecomponents. For all metallic materials the recycling is considered as the waste scenario.The data have the following characteristics:• many data are not lied to a geographic area, other are lied to Europe and to Holland.• When it had been possible, we have used the data extracted from the database of the code SimaPro3.1. Some new
materials and processes had been created by using data from literature or obtained by manufacturing firms.• The methods used are reproducible but do not consider all the emitted substances.• The databases are named IDEMAT 96 and PRé.
∗
Correspondence: Email: neri@bologna.enea.it; Telephone: 39 51 6098518; Fax: 39 51 6098594
2. THE INVENTORY
The inventory of the lamp, whose components are shown in Fig.1, was executed on the basis of flow-chart printed inFig.2.
Fig.1 The lamp components
2.1 Criteria used for the inventory definition.
The criteria for the inventory definition are the following:• we have considered the production of the materials and the transport from the material providers to the component
manufacturers.• We have considered the manufacturing of all components• The firm BEGHELLI executes the assembling of the electronics components on the board, the injection moulding
of the plastic components, the final assembly of the components, the testing and the packaging.• Moreover we have considered the distribution of the lamp assuming that inland, international and intercontinental
commerce is 85%, 5%, and 10% of the total commerce respectively.• We have assumed that the life of the lamp is 10 years.• The present end of life of the lamp (excluding the accumulator and the fluorescent tube) is a crushing process that
allows the recycling of the principal metallic materials. In this study we have not considered the crushing processand have assumed that all the separable materials are recycled. Among the materials that are not manuallyseparable, the plastic materials connected to the metallic ones are incinerated without energy recovery, the plasticmaterials constituted by not compatible polymers are incinerated with energy recovery. For the mercury andsulphuric acid we have assumed the reuse.
2.2 General description of inventory.
The lamp is formed by 13 components some of which we have arranged in the groups shown in Fig.3:
Fig.2 Flow chart of the life cycle of the lamp
TransportRawmaterialsEnergyMaterialsComponentmanufacturedoutside the firmLampComponentmanufacturedinside the firmManufacturingscrapsUseEnd of lifeIncinerationReuseRecycling• the two wiring harnesses (components 7 and 8) that connect the electronic card with the battery and the fluorescent
tube respectively.• The components 3, 4, 11 (neon holder, led support and battery bracket) that have a function of support of other
components. Moreover the neon holder generates the discharge that permits the lamp ignition and the diffuser ledamplifies the light of the led placed on the card.• The components 1, 5, 10, 13 (frame and glass, parabolic diffuser, screws, pack and gasket).
The other components are: electronic card (comp.9), fluorescent tube (comp.2), battery (comp.6) and electricalconnector (comp.12).The total lamp ‘life cycle’ is obtained by the contribution of several different LCA:• ‘life cycle’ of each component• ‘life cycle’ of packaging• ‘life cycle’ of the electric energy for the component assembling and use• ‘life cycle’ of the transports for distribution and servicing.2.2.1 The ‘disposal scenarios’ of the component materials.
• For those plastic materials with ‘disposal fraction’ thermoplast and PVC, that are considered inseparable from themetallic ones, we have created two new ‘waste treatments’ obtained from incineration thermoplast and incinerationPVC by removing the energy recovery. In the following cases like:a) the metallic materials with ‘disposal fraction’ non ferrob) the metallic materials with ‘disposal fraction’ Aluminiumc) the metallic materials with ‘disposal fraction’ copperwe have created new ‘waste treatments’ in respect to those foreseen by the SimaPro 3.1 database.
Fig.3 The flow-chart of the lamp components
ENERGYTRANSPORTComp.9CardComp.2FluorescenttubeComp.6BatteryComp.7-8WiringharnessesComp.3-4-11Neon holderLed supportBatteryBracketSupportsComp.1-5-10-13Frame-glassDiffuserScrewsPack-gasketStructureComp.12StudterminalblockIndustrial plantofPieve PelagoASSEMBLYIndustrial plant ofSavignoIndustrial plantof MonteveglioPACKAGINGTab.1 Data set for the ‘waste treatment’ of the lead
INPUT
Process name Def.Material/Fraction
recycling leadmod Non-ferro
Amount Un. Comment
26003.66 ton (17000+485+8500+18.66)Raw materials Amount Un. Commentwater 28900 ton
Others Amount Un. Commenttruck long-distance B 0.25 tkm estimatedelectr. Med. V. UCPTE 3385258 kWh estimated energyEnergy gas 26362875 kWhOUTPUT
Airborne emissions Amount Un. CommentPb 151.8 kgSO2 1578.72 kgNO2 15936.24 kgNO 537.34 kg
dust (coarse) 607.2 kg
Waterborne emissions Amount Un. CommentSolid emissions Amount Un. Commentindustrial waste 8500 ton scorie
chemical waste 485 ton PVC and ebanite (dangerous waste)Avoided products Amount Un. Comment
Lead I 17000 ton secondary production of lead
• For the lead contained in the battery we have created a new ‘waste treatment’ shown in Tab.1 that has as ‘avoided
3
product’ the material lead I. This treatment is obtained by literature.• The sulphuric acid, used as electrolyte of the battery, we have assumed that the 90% is reused and the 10% is
treated and disposed as toxic waste.• For the mercury vapour we have assumed that the 20% goes out of the tube during the lamp use and the 80% is
reused.2.2.2. The transports.
We have considered that:• the transports for the production of the materials are included in the ‘materials’.• The transports of the commercial components, assembled in the plants BEGHELLI, are included in the ‘life cycles’
of the components.• The transports for the lamp distribution, by truck in Italy and in Europe, by ship for going to America, are
considered in the ‘life cycle’ of the lamp.• The transport for servicing is considered in the ‘life cycle’ of the lamp.2.2.3 The energy.
We have considered that:• the energy for the production of the materials and components is considered in the ‘materials’ and in the
‘processes’.• The energy for the assembling (direct use) of the components, 3.03 min working time, is considered in the ‘life
cycle’ of the lamp and is calculated as 0.391 kWh.• The energy for indirect use (for example lighting and heating of plants) during the assembling of the components is
considered in the ‘life cycle’ of the lamp and is calculated like 0.255 kWh.• The energy of the use of the lamp is considered in the ‘life cycle’ of the lamp and is obtained as 4.406 kWh.2.2.4 The new processes.
We have created the following new processes in respect to those present in the SimaPro 3.1 database:• baking of the electric transformer.• Baking for sintering of the ferrite of transformer and inductor.• Baking for sintering of the carbon resistance of the electronic card.• Production of the mercury.• Metalization of the parabolic diffuser (Tab.2)• Manufacturing of the printed circuits of the board of the card• Welding of the electronic components on the printed card (Tab.3).For the phosphatizing of the fluorescent tube we have used the ‘process’ phosfating (Fe, s)Tab.2 Data set of the process of metalization of the parabolic diffuser.
INPUT
Raw materials Amount Un. CommentOthers Amount Un. Comment
furnace gas 0.006 MJ baking at 60°C of the plastic supportfurnace gas 0.0018 MJ 60°C temperature keepingelectr. Med. V. UCPTE 0.0333 kWh 1 kW for 120 sec (metalization)electr. Med. V. UCPTE 0.05 kWh 1 kW for 180 sec (polymerization)OUTPUT
Airborne emissions Amount Un. CommentWaterborne emissions Amount Un. CommentSolid emissions Amount Un. CommentMain products Amount Quantity Un.metalization Al 2.2457 Mass gPct. Sub-category
100 Non ferro
Avoided products Amount Un. Comment
Tab.3 Data set of the process of card welding
INPUT
Raw materials Amount Un. CommentOthers Amount Un. Commentelectricity Italy 0.0614 kWh
Lead I 1.591 g 4.3g*0.37Tin I 2.709 g 4.3g*0.63OUTPUT
Airborne emissions Amount Un. CommentWaterborne emissions Amount Un. CommentSolid emissions Amount Un. CommentMain products Amount Quantity Un.Card welding 4.3 Mass gPct. Sub-category
100 others
Avoided products Amount Un. Comment
3 LCA OF LAMP CALCULATED BY ECO-INDICATOR 95 EUROPE G METHOD
In the Eco-indicator 95 method the weights of normalisation are divided for a factor 10 for taking in account the lifetime of the functional unit (lamp).
3.1 Evaluation.
In Tab.4 and Fig.4 are reported the principal results of the evaluation.
Tab. 4 ‘Life cycle’ of the lamp
LCA COMPONENTSEnergy for the lamp useTransport of the lampStructure
Wiring harnessSupport
Stud terminal blockCardBatteryPackaging
Fluorescent tubeTotal lamp
NAMES OF LCACOMPONENTSlca energia est.complca trasporti est.complca struttura lampadalca cablaggi
lca funz.sostegnolca inst.morsettieralca schedalca batterialca imballaggio
lca tubo fluorescente
N°1111111211
DAMAGE [µPT]by Eco-indicator 9596796.146594.238.310136666623.498.82918
DAMAGE [µPT] by Eco-indicator 95 modified103998.1161610569.2197828187530.51025964
Fig.4 Evaluation diagram of the lamp ‘Life cycle’From the analysis of the results we can see that:• The total damage is 2918 µPt using the first method• The damage due to energy for the lamp use is 967 µPt.• The damage for the component production is 1921.9 µPt• The most dangerous components are: the battery that has a life of 5 years (666 µPt), structure (465 µPt) and the
card (366 µPt).• The plastic components produce a damage greater than the metallic components because the end of life of the
plastic materials is more dangerous than the one of the metallic materials.The damage categories with the most great values of damage are:• acidification (960 µPt) due chiefly to lead production and electric energy for the lamp use• carcinogenic (730 µPt) due chiefly to electric energy for the lamp and to processes to obtain fluorescent tube and
card• heavy metals (390 µPt) due chiefly to electric energy for the lamp use and to waste treatment of battery.3.2 Evaluation of the card
Tab. 5 and Fig. 5 show the damages of the card and of its components.
Tab.5 The damage of the card components.
LCA COMPONENTSNAMES OF LCA
COMPONENTS
Supportlca sup scheda modElectrical transformerlca trasf.alimentaz.Ferrite transformerlca trasf.sc. ferriteFerrite inductorlca indut. sc.ferriteElectrical connectorlca morsettiera sch.Connectorslca connettori schedaCondenserslca cond. schedaResistancelca res.schedaTransistorlca transistor schedaDiodes – led - ciplca diodi-led-cipTrimmerlca trimmer schedaElectric energyEnergia el. schedaWelding cardSaldatura schedaTransportsTruck ITotal card
N°11111111111111
DAMAGE
[µPt] by Eco-indicator 9515684.619.021.45.504.038.0418.04.262.263.4518.7200.26366
Fig.5 The diagram of the LCA evaluation of the card components.
From the results we can see that the components that produce the most damages are the card support (acidification andwinter smog) and the electrical transformer (carcinogenic and heavy metals).4 LCA OF LAMP WITH ECO-INDICATOR 95 EUROPE G METHOD MODIFIED.
The Eco-indicator 95 was modified by introducing some new damage categories related to depletion of minerals (Al,Cu, Fe, Hg, Ni, Pb, Zn) and fossil fuels (coal, gas, oil), by considering also the normalisation and the evaluation forsolid and also the evaluation for energy.4.1 Evaluation.
Tab.4 (last column) and Fig.6 show the principal results of the evaluation of the ‘life cycle’ of the lamp.
Fig.6 Evaluation diagram of the lamp ‘Life cycle’ calculated by Eco-indicator 95 modified
From the results we can see that the greater damages of the new damage categories are:• 2190 µPt for solid due mainly to the structure• 810 µPt for Pb depletion due mainly to the battery.It has to be noted that this second method permits to put in evidence the importance of the above mentioned categoriesthat in the first method do not appear.
5 COMPARISON WITH MATERIALS AND PROCESSES THAT PRODUCE A DAMAGE EQUAL
TO THE ONE OF THE LAMP.
By Eco-indicator 95 method we have calculated the quantities of materials, processes, energies and transports thatproduce the damage of the lamp as 2918 µPt. From these results we can see that the studied lamp produces in 10 yearsthe same damage of a refrigerant with a capacity of 250 l during 11.5 day of running, of 5 cycles of a washer machinewith a power of 1.5 kW, of 2.5 heating of 80 l of water to 60 °C by means of an electric boiler, of the production of145.5 kg of paving tiles, of 8.5 kg of iron and of 13 kg of aluminium.
6 PROPOSALS TO REDUCE THE LAMP DAMAGE.
The LCA study has permitted to determine some modifications of the lamp design that can decrease its environmentaldamage. Here we report some modifications among those studied.
6.1 Replace of materials and processes.• To separate different plastic materials we propose to use a separable gasket. With this modification the end of life
of the sheath becomes the recycling of the sheath and the incineration of the gasket.• To recycle the plastic material of the parabolic diffuser we propose to replace a metalization process with a foil of
aluminium pinned by 4 dog clutches on the parabolic diffuser. With this modification also the aluminium can berecycled. We propose also to replace the material of the parabolic diffuser (ABS) with PC. The Fig.7 shows thecomparison of the damages due to the present parabolic diffuser (106 µPt for lca para.metallizzata) and theproposed one (48.9 µPt for lca para.metallizzPCI) parabolic diffuser.Fig.7 Comparison of the damages of the actual and the proposed parabolic diffusers.• The European directive WEEE foresees the exclusion of the lead and bromine within the year 2004. We propose toreplace the SnPb alloy used for the welding to fix the electronic components on the card support with the alloy77.2Sn/20In/2.8Ag.• To reduce the amount of materials necessary for the card we propose to use the SMD technology for assembling
the electronic components on the board.• To reduce the consumption of electric energy we propose the following modification to the card:
1. use of transistors ‘Mosfet’ (electronic ballast) with a greater efficiency: energetic saving of 10%2. Use of a commutation governor rather than a linear governor: energetic saving of 8-10%
3. Use of a transformer with fixed foils rather than that with welded foils: energetic saving of 15-20%
4. Use of a photoelectric cell to check the lighting of the room during the diurnal hours when the natural light
makes useless the ignition of the lamp.
5. Use of smaller electronic components suitable at SMD technology that have lower dissipation.
7. INDICATIONS FOR THE DEFINITION OF THE ECOLABEL OF THE LAMP.
From the LCA study of the lamp we can present some indications to get of the lamp ecolabel. It is therefore necessaryto define:
1. the upper limit of the consumption of electric energy.2. The limit of amount of mercury in the fluorescent tube.
3. The limit of lead used for the welding the components to the card.4. The procedure to apply the design for Disassembly technique.5. The lamp life.
References
Buttol P., Cecchini F., Danielli G., Neri P., Pareschi R., Tani G.LCA di una lampada di emergenza prodotta dallaDitta BEGHELLI Spa e proposta per un suo ecolabel.Doc. ENEA OT-SBB-00011, Bologna 8/6/20002
Goedkoop M. SimaPro 3.1. PRé Consultants, Bergstraat 6, 3811 NH Amersfoort, the Nederlands, 19953
Picini P., Santino D.. Analisi energetico – ambientale degli interventi per l’abbattimento dei consumi del piombo neiprocessi industriali. Doc. ENEA AMB-CAT-URM
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