1. WP4 – Task 4.3 LCA Activities
Innovative recycled plastic based panels for building field
30° Month MEETING
Madrid February 6, 2014

2. Contents EcoPlasBrick panel general description LCA – Phases
LCA – Goal and scope
LCA – Inventory Analysis (LCI)
LCA – Impact Assessment (LCIA)
LCA – Interpretation
Status in brief
Deliverable D4.2
November 2013
Deliverable D4.3
January 2014
30° MONTH MEETING - Madrid, February 6, 2014

3. Deliverable D4.2
D – LCA phase I: Definition of goal and scope, Data inventory
D – LCA phase II: Impact Assessment
30° MONTH MEETING - Madrid, February 6, 2014

4. EcoPlasBrick panel general description
Ecoplasbrick panel is a sandwich panel made of a core of recycled plastic waste (in form of densified flakes) mixed with Polyurethane resin, and two plasterboard skins. The panel frame is made of wood and steel plates.
In particular, the LCA will be performed on a specific panel used for vertical indoor rooms division. In the following are provided brief descriptions for the LCA phases, and the results achieved.
30° MONTH MEETING - Madrid, February 6, 2014

5. LCA – Phases
The LCA study is performed in accordance with internationally recognized guidelines (ILCD Handbook: General guide for Life Cycle Assessment - Detailed guidance) and standards (ISO 14044:2006 and ISO 14040:2006). It is structured in a series of steps, which are:
1. LCA goal & scope definition Inventory analysis (LCI)
3. Impact assessment (LCIA) 4. Interpretation
Goal and scope definition
Results interpretation and improvement analysis
Inventory analysis
Impact assessment
30° MONTH MEETING - Madrid, February 6, 2014

6. 3 step 1 step 2 step 4 step LCA – Phases Study scope System limits
Functional unit
System functions
Energy flows
Material flows
Emissions
1 step
2 step
3 step
Assessment method application
4 step
Identification of strategy intervention
30° MONTH MEETING - Madrid, February 6, 2014

7. “Cradle to grave” life cycle:
LCA – Goal and scope
Goal and Scope definition phase aims to define how big part of product life cycle will be taken in assessment and to what will assessment be serving. The criteria identified and specific time horizon are described in this step.
In particular, the analysis of the energetic and environmental impacts of the innovative recycled plastic based panel has been performed, considering
“Cradle to grave” life cycle:
Production process
Use phase
End of life
30° MONTH MEETING - Madrid, February 6, 2014

8. LCA – Goal and scope
In order to perform the LCA, a proper Functional Unit has been defined:
Functional unit is represented by 0.5 m2 of panel surface, with 0.09 m of thickness and kg of weight
All data regarding materials and energy consumption will be referred directly or through a proportion, to this functional unit
All calculated impacts (e.g. global warming potential, acidification potential, eutrophication potential, use of non renewable resources, etc.) will be referred to the selected functional unit
30° MONTH MEETING - Madrid, February 6, 2014

9. LCA – Inventory analysis (LCI)
Inventory analysis is the description of material and energy flows within the product system and especially its interaction with environment, consumed raw materials and emissions to the environment. All important processes and subsidiary energy and material flows are described here.
In the following all the collected information on the EcoPlasBrick panel are reported.
30° MONTH MEETING - Madrid, February 6, 2014

10. LCA – Inventory analysis (LCI)
Main components of the panel:
Skin material constituted by 1 cm (thickness) of plasterboard on both side of the panel. The plasterboard density is kg/m3
Core material made of 6-10 cm (thickness) of mixed densified plastic waste, polyurethane foam and water
Woody frame constituted by:
Wood: total weight of 1.5 kg
Steel plates: total weight of kg
30° MONTH MEETING - Madrid, February 6, 2014

11. LCA – Inventory analysis (LCI)
Core composition:
Densified material + polyurethane foam + water
Core total weight: kg
Densified material:
Aggregate weight: kg
Available LCA for other data
Polyurethane foam:
Polyurethane weight: kg
Water used as activator:
Water weight: kg
The densified material is mixed with the polyurethane and water by using a mixer (1.5 CV) for 2-15 minutes.
30° MONTH MEETING - Madrid, February 6, 2014

12. LCA – Inventory analysis (LCI)
Production process of the panel:
A first layer of skin (plasterboard) is placed in a mold
The densified material-polyurethane mix is put on the skin layer in the mold
The second layer of skin is placed on the mixture
The panel made of the three layers is pressed by using simple clamps
The cure phase takes around minutes at 15°-60°C
The densified material is transported from Treviso (Centro Riciclo Vedelago)
The polyurethane foam is transported from Correggio, Reggio Emilia
The materials used to build the panel frame are provided by local producers.
30° MONTH MEETING - Madrid, February 6, 2014

13. Impact category (ILCD guidelines)
LCA – Impact Assessment (LCIA)
Impact assessment is based on the details from Inventory Analysis
Impact category (ILCD guidelines)
Units
EDIP 2003, Stratospheric ozone depletion
[kg R11-Equiv.]
Acidification, accumulated exceedance
[Moles of N or S- Equiv.]
CML2002 Resource Depletion, fossil and mineral, reserve Based
[kg Sb-Equiv.]
IPCC global warming, incl biogenic carbon
[kg CO2-Equiv.]
Particulate matter/Respiratory inorganics, RiskPoll
[kg PM2,5-Equiv.]
Terrestrial eutrophication, accumulated exceedance
Total freshwater consumption, including rainwater (acc. to UBP 2006)
[kg]
ReCiPe 1.07 Midpoint (H) - Freshwater eutrophication
[kg P eq]
ReCiPe 1.07 Midpoint (H) - Ionising radiation
[kg U235 eq]
ReCiPe 1.07 Midpoint (H) - Photochemical oxidant formation
[kg NMVOC]
USEtox, Ecotoxicity (recommended)
[CTUeco]
USEtox, Human toxicity, cancer (recommended)
[CTUh]
USEtox, Human toxicity, non-canc. (recommended)
Land Transformation Indicator
[sqm]
30° MONTH MEETING - Madrid, February 6, 2014

14. LCA – Impact Assessment (LCIA) results
The indicator results of all impact categories for Panel manufacturing, Use phase and End of Life are here reported:
30° MONTH MEETING - Madrid, February 6, 2014

15. Indicators calculated with the new methods
LCA – Interpretation
Interpretation of life cycle involve critical review, determination of data sensitivity and result presentation
LCIA results update: Update of the GaBi software realized in order to be fully compliant to PEF (Product Environmental Footprint) recommendation 2013/179/EU
Indicators calculated with the new methods
Updated indicators
Terrestrial eutrophication, accumulated exceedance
Acidification, accumulated exceedance
Freshwater eutrophication, EUTREND model, ReCiPe
Resource Depletion, fossil and mineral, reserve Based, CML2002
Marine eutrophication, EUTREND model, ReCiPe
IPCC global warming, incl biogenic carbon
Photochemical ozone formation, LOTOS-EUROS model, ReCiPe
Particulate matter/Respiratory inorganics, RiskPoll
Total freshwater consumption, including rainwater, Swiss Ecoscarcity
Ionising radiation, human health effect model, ReCiPe
Ecotoxicity for aquatic fresh water, USEtox
Ozone depletion, WMO model, ReCiPe
USEtox, Human toxicity, cancer
USEtox, Human toxicity, non-canc
DEVIATIONS ARE MINOR!!!
30° MONTH MEETING - Madrid, February 6, 2014

16. LCA phase III: Interpretation of results
Deliverable D4.3
LCA phase III: Interpretation of results
30° MONTH MEETING - Madrid, February 6, 2014

17. LCA – Interpretation
Interpretation of life cycle involve critical review, determination of data sensitivity and result presentation
The following analyses have been performed:
Hot spot Analysis
Sensitivity Analysis
Normalization
30° MONTH MEETING - Madrid, February 6, 2014

18. LCA – Interpretation
Hot Spot Analysis: Identify the processes that are the main responsible of environmental impacts
The manufacturing phase is the phase in which the most impacting contributions are present.
For each indicator the one/two main contributor(s) have been identified and also their shares compared to total value have been calculated.
Results: Polyurethane and Gypsum plaster board production are the heaviest phases from the environmental point of view. For GWP also the energy used for densified flake production contributes to total indicator value.
30° MONTH MEETING - Madrid, February 6, 2014

19. Sending to landfill of core and skin
LCA – Interpretation
Sensitivity Analysis: Identify and focus on key data and assumptions that have most influence on a result
Data on manufacturing process are quite accurate, due the direct interaction with manufacturer. Instead uncertainties are present on transport contributions (before and after the production) and end of life options. The following assumptions have been made:
Original Input Data
Assumptions
Distance from PU foam provider to Motulab facilities
451 V1
451*3=1353 V2
451*0.5=225.5
Distance between Motulab facilities and installation site
250 V3
1000
End of life of the panel
Step 1: Disassembly of core, skins and steel plates
Step 2: Core: Recycling, Skin: Incinerator, Steel plates: Recovery V4
Sending to landfill of core and skin V5
V1+V3+V4
30° MONTH MEETING - Madrid, February 6, 2014

20. LCA – Interpretation
Sensitivity Analysis: identify and focus on key data and assumptions that have most influence on a result
OPTION V1: The distance between PU foam provider and Motulab facilities has been shifted from 451 to 1353 km
Results: The only important variations over 10% regards Human Toxicity – Non cancerogenic.
Further noticeable variations affect Marine Eutrophication (8.18%) and Terrestrial Eutrophication (48.5%)
30° MONTH MEETING - Madrid, February 6, 2014

21. LCA – Interpretation
Sensitivity Analysis: identify and focus on key data and assumptions that have most influence on a result
OPTION V2: The distance between PU foam provider and Motulab facilities has been split in half from 451 to km
Result: No important variations are present
30° MONTH MEETING - Madrid, February 6, 2014

22. LCA – Interpretation
Sensitivity Analysis: identify and focus on key data and assumptions that have most influence on a result
OPTION V3: The distance between Motulab facilities and estimated installation site has been shifted from 200 to 1000 km
Results: The hypothetical enlargement of the market in terms of area of deliveries, entails an evident increase of several indicators. In particular:
Human Toxicity (non cancer) becomes an impact, while was a benefit (credit) in standard conditions.
Acidification (31.67%)
Marine (86.21%)
Terrestrial Eutrophication (51.16%)
30° MONTH MEETING - Madrid, February 6, 2014

23. LCA – Interpretation
Sensitivity Analysis: identify and focus on key data and assumptions that have most influence on a result
OPTION V4: Except steel plates which are still sent to recovery, the other panel components (core and skin) are sent directly to landfill
Results:
The recourse to landfill have an important impact on:
Freshwater
Eutrophication
Particulate Production
Human Toxicity (non cancer)
Ozone Depletion
Global life cycle still generates benefits (thanks to the recycling of materials) even if lower than standard option
30° MONTH MEETING - Madrid, February 6, 2014

24. OPTION V5: Combination of V1,V3 and V4
LCA – Interpretation
Sensitivity Analysis: identify and focus on key data and assumptions that have most influence on a result
OPTION V5: Combination of V1,V3 and V4
Results: The worst conditions generate the worst impacts in terms of environmental and energetic performances.
The main impacts affected by these variations (over 100%) are:
Freshwater Eutrophication
Human Toxicity, non cancer (which become an impact while in standard condition were avoided impacts)
Particulate Matter production
Marine Eutrophication (increases the impact value)
Ozone Depletion (avoided impact is reduced by almost 90%)
30° MONTH MEETING - Madrid, February 6, 2014

25. LCA – Interpretation
Normalization: The different characterized impact scores are related to a common reference. The term of comparison used is the annual environmental impact of an European citizen equivalent
Considerations:
Some impact categories do not have a normalization value referred to person equivalent
If the global value of an indicator is negative (benefit for the environment) it has no sense to define a normalization value
Normalization methods used:
USEtox Europe
ReCiPe 1.08 (E)
IPCC, EU25+3
30° MONTH MEETING - Madrid, February 6, 2014

26. LCA – Interpretation
Normalization: The different characterized impact scores are related to a common reference. The term of comparison used is the annual environmental impact of an European citizen equivalent
Results: As regards climate change indicator, for instance, an Ecoplasbrick panel, assuming the conditions expresses in LCI, has an impact equal to 1.799*E-03 person
556 m2 of Ecoplasbrick panel ≡ 1 Equivalent European Person/ year
30° MONTH MEETING - Madrid, February 6, 2014

27. LCA – Interpretation Reccomandations:
The hot spot analysis highlights that the primary impact in all main indicators is “RER: Polyurethane rigid foam (PU) Plastic Europe”, in some case reaching up to 80% of the overall impacts.
Huge amount of recycled materials are generating “avoided impacts” thus decreasing the overall figure. This is critical and it is recommended in the real case to implement this “recycling material chain” to support the above quoted hypothesis.
30° MONTH MEETING - Madrid, February 6, 2014

28. Status in brief LCA Phase Report Delivery Goal and Scope Definition
15 November 2013
Inventory analysis
Models preparation
Impact assessment
D4.2.2
Interpretation
D4.3
31 January 2014
Technical documentation for Environmental Product Declaration
D4.4
June 2014
30° MONTH MEETING - Madrid, February 6, 2014

29. Questions?
30° MONTH MEETING - Madrid, February 6, 2014

30. Thank you for your kind attention!
Daniela Reccardo
30° MONTH MEETING - Madrid, February 6, 2014