Case Study: Life Cycle Assessment Of Plastic Shoe Rack Using Injection Molding Machine

Transcription

1 Case Study: Life Cycle Assessment Of Plastic Shoe Rack Using Injection Molding Machine SHARAH YUNIHAR SAPUTRA, DR. JESSICA HANAFI UNIVERSITAS PELITA HARAPAN

2 Background Plastic industries in Indonesia is one of the most popular industry that is used by businessmen as their investments. According to the data issued by the ministry of industries in Indonesia in 2013, there are more than 890 plastic industry in Indonesia. It is supported by the high levels of consumption of plastics, up to 1.9 million tons (2013) Plastics take a long time to decompose naturally at the end of its life cycle. This can affect the environment. Not all plastics are biodegradable, for instance the plastics used in non packaging plastics. The effects of plastics may not appear at the end of its life cycle alone, but also from other parts of its life cycle.

3 Research Method LCA Method LCA Method Source: US EPA

4 Phase 1 of LCA: Goal Definition and Scope Goal: Studying the LCA of plastic products that has a high level of production and consumption, with examples taken from productions by the means of injection molding. Scope: Case study of plastic shoe rack with a weight of 1.24 kg each and is mainly constructed from Polypropylene that is produced by Union Plastik company. The company was established 30 years ago and has a production facility in Kapuk, North Jakarta.

5 Data Collection Assessed Product: Plastic Shoe Rack

6 Product Structure Tree

7 Production Processes Mixing Molding Inspection & Scrap cleaning Yes Assembly Packaging No Crushing

8 Molded Parts from Injection Molding Machines Rack Shelf Rack Foot Pok-Dop

9 Phase 2 of LCA: Life Cycle Inventory LCI of Rack Shelf (in 1 shift of Production = 8 hours)

10 Phase 2 of LCA: Life Cycle Inventory (Cont d) LCI of Rack Shelf (in functional unit = 1 kg)

11 Phase 2 of LCA: Life Cycle Inventory (Cont d) LCI of Rack Foot (in 1 shift of Production = 8 hours) LCI of Rack Foot (in functional unit = 1 kg)

12 Phase 2 of LCA: Life Cycle Inventory (Cont d) LCI of Pok-Dop (in 1 shift of Production = 8 hours) LCI of Pok-Dop (in functional unit = 1 kg)

13 Phase 2 of LCA: Life Cycle Inventory (Cont d) LCI of Crushing (3 shift) LCI of Crushing (in functional unit = 1 kg)

14 Phase 3 of LCA: Life Cycle Impact Assessment LC Shoe Rack Shoe Rack Rack Shelf Rack Foot Pok-Dop Network diagram of Plastic Shoe Rack s Life Cycle, result from SimaPro LCIA calculation using ReCiPe Endpoint Method

15 Phase 3 of LCA: Life Cycle Impact Assessment (Cont d) Midpoint: IPCC TRACI CML-IA BASELINE ReCiPe Midpoint Endpoint: ReCiPe Endpoint

16 Phase 3 of LCA: Life Cycle Impact Assessment (Cont d) IPCC Method Rack Shelf Rack Foot Pok-Dop GWP value = 7.45 kg CO 2 eq

17 Phase 3 of LCA: Life Cycle Impact Assessment (Cont d) IPCC Method Process Contribution Process Unit Total Rack Shelf Rack Foot Pok-Dop Printed paper Packaging film, PE Transport Disposal Product Total for All Processes kg CO2 eq Polypropylene, granulate kg CO2 eq Electricity, high voltage kg CO2 eq Toner, colour, powder kg CO2 eq Packaging film, PE kg CO2 eq Transport kg CO2 eq Printed paper kg CO2 eq Injection Moulding Nangrong kg CO2 eq Injection Moulding, kg CO2 eq ISYM1600 Injection Moulding, CLF kg CO2 eq T Disposal Product kg CO2 eq Crushing kg CO2 eq Coloured PP kg CO2 eq

18 Phase 3 of LCA: Life Cycle Impact Assessment (Cont d) TRACI Method Rack Shelf Rack Foot Pok-Dop

19 Phase 3 of LCA: Life Cycle Impact Assessment (Cont d) TRACI Method Normalization Inventory # Impact category Unit Total Rack Shelf Rack Foot Pok-Dop Printed paper Packaging film, PE Transport Disposal Product 1 Carcinogenics Ecotoxicity Eutrophication Non carcinogenics Fossil fuel depletion Respiratory effects Global warming Acidification Smog Ozone depletion

20 Phase 3 of LCA: Life Cycle Impact Assessment (Cont d) CML-IA Baseline Method Rack Shelf Rack Foot Pok-Dop

21 Phase 3 of LCA: Life Cycle Impact Assessment (Cont d) CML-IA Baseline Method Normalization Inventory # Impact category Unit Total Rack Shelf Rack Foot Pok-Dop Printed paper Packaging film, PE Transport Disposal Product 1 Marine aquatic ecotoxicity 3.68E E E E E E E E-13 2 Abiotic depletion (fossil fuels) 6.71E E E E E E E E-14 3 Fresh water aquatic ecotox. 2.98E E E E E E E E-14 4 Global warming (GWP100a) 1.46E E E E E E E E-14 5 Acidification 1.07E E E E E E E E-14 6 Eutrophication 7.97E E E E E E E E-14 7 Photochemical oxidation 1.90E E E E E E E E-15 8 Human toxicity 1.74E E E E E E E E-15 9 Terrestrial ecotoxicity 8.47E E E E E E E E Abiotic depletion 1.33E E E E E E E E Ozone layer depletion (ODP) 2.04E E E E E E E E-17

22 Phase 3 of LCA: Life Cycle Impact Assessment (Cont d) ReCiPe Midpoint Method Rack Shelf Rack Foot Pok-Dop

23 Phase 3 of LCA: Life Cycle Impact Assessment (Cont d) ReCiPe Midpoint Method Normalization Inventory # Impact category Unit Total Rack Shelf Rack Foot Pok-Dop Printed paper Packaging film, PE Transport Disposal Product 1 Fossil depletion E E E E-06 2 Climate change Human Health E E E E E-06 3 Particulate matter formation E E E E E E-05 4 Human toxicity 8.6E E E E E E E E-06 5 Climate change Ecosystems 6.4E E E E E E E E-07 6 Metal depletion 9.7E E E E E E E E-07 7 Natural land transformation 7.2E E E E E E E E-08 8 Urban land occupation 4.3E E E E E E E E-09 9 Agricultural land occupation 3.3E E E E E E E E Terrestrial acidification 1.7E E E E E E E E Ionising radiation 1.6E E E E E E E E Freshwater eutrophication 1.1E E E E E E E E Photochemical oxidant formation 8.2E E E E E E E E Freshwater ecotoxicity 4.3E E E E E E E E Terrestrial ecotoxicity 3.9E E E E E E E E Ozone depletion 3.5E E E E E E E E Marine ecotoxicity 8.4E E E E E E E E-10

24 IPCC Presented at Workshop on Life Cycle Assessment Research in Indonesia, Puspiptek-Serpong, November Available in the respective author(s). TRACI CML-IA Baseline ReCipe Methods Election Calculate only one category: GWP In other methods, GWP is not a significant impact category Carcinogenic has a significant impact Carcinogenic has big enough difference in the normalization value with category #2 and #3 Marine Aquatic Eco-toxicity has a significant impact Compare to TRACI, Marine Aquatic Ecotoxicity NOT has big enough difference in the normalization value with category #2 and #3 First three categories show that they have significant impact

25 LCIA Analysis based on Chosen Methods RECIPE MIDPOINT 1. Fossil Depletion 2. Climate Change Human Health TRACI 1. Carcinogenic 2. Eco-toxicity 3. Eutrophication 3. Particulate Matter Formation

26 #1 FOSSIL DEPLETION #1 CARCINOGENIC Main substance: Oil Crude (63.84% contribution) Main substance: Chromium (VI) compartment in Water (94.44% contribution) Electricity 6.35% Other Processes 2.52% Other Processes 5.05% Electricity 44.78% PP 50.17% PP 91.13%

27 #2 CLIMATE CHANGE HUMAN HEALTH #2 ECO-TOXICITY Main substance: CO 2 (88.20% contribution) Main substance: Zink compartment in water (35.93%), Antimony/Sb (16.26%) dan Nickel (14.15%). Electricity 25.56% Other Processes 5.72% Other Processes 6.28% PP 15.88% PP 68.72% Electricity 77.84%

28 #3 PARTICULATE MATTER FORMATION Main substance: Particulates, < 2.5 um released in air (71.22% contribution) #3 EUTROPHICATION Main substance: Phosphate (76.07% contribution) Other Processes 1.38% PP 1.04% Toner 4.59% Other Processes 0.78% PP 3.5% Electricity 97.58% Electricity 91.13%

29 Midpoint-to-Endpoint Relation % % 2.01% Rack Shelf Rack Foot Pok-Dop

30 Midpoint-to-Endpoint Relation (Cont d) Electricity is generated from Fossil Depletion PP Usage Electricity Usage the combustion of crude oil, and PP is made from the crude oil Resources

31 Midpoint-to-Endpoint Relation (Cont d) Increase of diseases due to the increase of Green Climate Change House Gas Resource depletion Carcinogenic Particulate Matter Formation Respiratory disorders Human Health

32 Midpoint-to-Endpoint Relation (Cont d) Damage of water ecosystem Eutrophication Eco-toxicity Lowering of water quality Unbalanced ecosystem Ecosystem Human Health

33 Phase 4 of LCA: Interpretation Life cycle that uses the most material and energy is the process of shoe rack production in manufacture using Injection Molding machine, with rack shelf part which contribute the most. The life cycle of the shoe rack in midpoint causes a significant fossil depletion, climate change-human health, particulate matter formation, carcinogenic, eco-toxicity and eutrophication.

34 Phase 4 of LCA: Interpretation (Cont d) LCIA breakdown (Contribution > 50%): Crude oil (63.84%), Carbon Dioxide (88.20 %), Airborne Particulates < 2.5 um (71.22%), Chromium VI (94.44%), Phosphate (76.07%). Eco-toxicity: Zinc that is dissolved in water (35.93%), followed by Antimony/Sb (16.26%) and Nickel (14.15%) Significant effects come from the use of electricity and PP. At the endpoint, the damage is significant towards resource and human health.

35 Phase 4 of LCA: Interpretation (Cont d) Evaluation: The usage of renewable energy it is advisable to use energy saving machines Combine the usage of PP with PET to make it more environmental friendly. The usage of masks in the workspace.

36 Thank you.