1 ECOFATTING Alessandra Zamagni– ENEA Pier Luigi Porta - ENEA Italian National Agency for New Technologies, Energy and Sustainable Economic Development

1

ECOFATTING

Alessandra Zamagni– ENEAPier Luigi Porta - ENEA

Italian National Agency for New Technologies, Energy and Sustainable Economic DevelopmentUTVALAMB LCA and Ecodesign Laboratory (Bologna, Italy) Ecofatting LIFE10 ENV/IT/364Technical and Progress Meeting - Pisa, 11 December 2013

Use of Environmentally friendly natural products instead of chloroparaffines in the fatting phase of the tanning cycle

Pisa, 11 December 2013

2

Purposes: To assess the environmental profile of the ECOFATTING

process To compare the ECOFATTING process with the present

technology based on chloroparaffins.

Method: Life Cycle Assessment (LCA), according to:

ISO 14040 and 14044 Product Environmental Footprint (PEF) guide

Action 8 – Study of the demonstration about the environmental benefits from the natural products fatting process


3

TEMPERATURE SETTING UP TO 1650 °C

Life Cycle Assessment

LCA is a technique for the systematic evaluation of the environmental aspects of a product or service system through all stages of its life cycle

The only standardised method to quantify a broad range of environmental impact categories

It provides scientific and quantitative information to identify/prevent environmental burdens shifting among the different phases of the life cycle, and the different impact categories

It allows for a comparative assessment between different product/services/systems performing the same function

Detailed approach: the contribution to the different impact categories of each elementary flows, of each unit processes, is accounted for

It support optimisation processes whenever a trade off exist.

Source: Lepech (2010), Stanford University,


4

The LCA framework

Life cycle assessment framework

Interpretation

Goal definition

Scope definition

Inventory analysis

Impact assessment

Direct applications:

• Product development and improvement

• Strategic planning• Public policy making• Marketing• Other

From ISO 14044:2006, modifiedplus Documentation, Review

From ISO 14044:2006, modified

Goal & Scope Definition Definition of the purpose and intended application of the study.

Inventory Analysis Compilation and quantification of inputs and outputs through the life cycle.

Impact Assessment Identification and evaluation of the magnitudes and relative importance of the environmental impacts arising from the inventory analysis.

InterpretationThe results are checked and evaluated to confirm that they are consistent with the goal of the study.


Pisa, 11 December 2013 5

LCA and the Ecofatting processGoal and Scope Definition Objective:

to assess the environmental profile of the ECOFATTING process To compare the ECOFATTING process with the present technology based on

chloroparaffins.

Intended audience: ENEA, project partners, LIFE+ Project Officer Functional unit: 1 kg of fat liquor compound used in the retanning

process. Impact categories and indicators:

The emissions of greenhouse gases-GWP, kg CO 2-equivalents, in 100 year perspective; Emission of ozone-depleting gases-kg CFC 11-equivalents, 20 years; Emission of acidification gases-kg SO2- equivalent; Emissions of gases that contribute to the creation of ground level ozone-kg ethene-

equivalents; Emission of substances to water contributing to oxygen depletion-kg PO 4 3--equivalents).

Other indicators needs to be included in order to measure important expected key results: reduction of water consumption during the tanning process; reduction of toxicity; reduction of energy consumption.


The fatting process

The traditional and Ecofatting process differ in the types of products used in the fatting phase during the leather tanning cycle Focus on the comparison between the two recipes: Chlorosulfonated products vs

esterified vegetable fatty acid derivatives

COMPONENT% (per ton of leather)

Ecofatting Product (FACL) 20,0

Lecithin 2,5

Sulphited triglyceride oil (90%) 30,0

Phosphated fatty alcohol 3,5

Oleic soap 3,0

Castor oil etoxilated 1,0

Sulphated hydrocarbon 10,0

Water 30,0

COMPONENT% (per ton of leather)

Ecofatting Product (FASCL) 20,0

Lecithin 2,5

Sulphited triglyceride oil (90%) 30,0

Phosphated fatty alcohol 3,5

Sodium Hydroxide 10,0

Castor oil etoxilated 1,0

FAMECL2 10,0

Water 23,0

FAME-Cl(as a substitute of CP44)

SFAME-Cl(as a substitute of SCP)


Life Cycle Inventory – the approach adopted

RETANNING

SAMMING

SPLITING

SHAWING

RETANNING

FATLIQUORING

DYEING

Leather life cycle (Source: Joseph et al. 2009)

Ecofatting


Life Cycle Inventory – the approach adopted

Fatliquoring retanning with (sulpho)chlorinated fatty acid from paraffin

RECIPE A

Fatliquoring retanning with palmkernel

(sulpho)chlorinated methyl-fatty acid ester

RECIPE B

vs

CLOPARIN 44FCLOPARTEN Z

FACLFASCL

PARAFFIN PALM KERNEL OIL

vs

vs

LCA-based information

LCA-based information

Process-related information


Life Cycle Inventory

Data and assumptions: Different yield for the production of (sulpho)chlorinated fatty acid from

paraffin and palmkernel (sulpho)chlorinated methyl-fatty acid ester 1 kg paraffin 1,81 kg Cloparin 44F; 1 kg FAME 1,92 kg FACL 1 kg paraffin 1,57 kg Cloparten Z; 1 kg FAME 1,90 kg FASCL

Co-products: hydrochloric acid (presently not allocated, but it does not affect the results

Chlorine and sulphur in excess are reduced and then sent to disposal The disposal treatment has not been considering (optimisation at the

industrial scale) Same quality of the leather after the treatment with the to products

(same softness, fullness, touch, dyebility, tanning power, loosen grain) Waste water treatment: environmental impact on waste water carried

out by INESCOP


Life Cycle Impact Assessment Cloparin 44F vs FACL

Characterisation results (CML, update nov. 2010)

Cloparin 44F vs FACL


Abiotic Depletion

Characterisation results (CML, Nov. 2010)


CLOPARIN 44FFACL


Global Warming



CLOPARIN 44FFACL


Life Cycle Impact AssessmentCloparin 44F vs FACL

Characterisation results (ReCiPe ) – focus on TOXICITY



Characterisation results (USEtox ) focus on TOXICITY

Life Cycle Impact AssessmentCloparin 44F vs FACL


FACL CLOPARIN 44F


Life Cycle Impact Assessment Cloparten Z vs FASCL

Characterisation results (CML, update Nov. 2010)

Cloparten Z vs FASCL


Abiotic Depletion


Cloparten Zvs FASCL

CLOROPARTEN ZFASCL


Global Warming


Cloparten Zvs FASCL

CLOROPARTEN ZFASCL


Global Warming



CLOROPARTEN ZFASCL


Characterisation results (ReCiPe) – focus on TOXICITY


Life Cycle Impact AssessmentCloparten Z vs FASCL


Life Cycle Impact AssessmentCloparten Z vs FASCL

Characterisation results (USEtox) – focus on TOXICITY


FASCL CLOROPARTEN Z


Energy consumption

Information on energy needed for the production of the inputs “palm kernel oil” and “paraffin” Life cycle-based data (Ecoinvent v2.2 database, peer reviewed articles) Sector specific literature

PALM KERNEL OIL Energy intensive process, with

thermal and electrical energy being the main contributors (dryer, cracker, roaster, crusher, oil-pressing machine, sifter and bottles pump)

Energy to produce 1 kg of palm kernel oil: 0.346MJ/kg (small mills) 0.217 MJ/kg (medium mills) 0.176 MJ/kg (large mills)

PARAFFIN Electricity: 0.093 MJ/kg Thermal energy: 4.58 MJ/kg

Source: Ecoinvent v2.2


Discussion

The results obtained will be further refined, investigating: Toxicity impact categories (environmental models still under development) Information on process water consumption of paraffin and palm kernel oil Optimisation of the production process in the upscale

Allocation between product and co-product has not been applied but the analysis carried out demonstrates that it does not affect the results

The LCA study points out not apparent conclusions Palm kernel oil: energy intensive production Benefit to be discussed at a broader scale, considering the marginal use of

the palm kernel oil

Final technical report of the LCA study under preparation


Alessandra Zamagni, Pier Luigi PortaLCA and Ecodesign Laboratory - ENEA

Via Martiri di Monte Sole, 440129 - Bologna

[email protected] ; [email protected]

Thank you for your attention

Documents

1 ECOFATTING Alessandra Zamagni– ENEA Pier Luigi Porta - ENEA Italian National Agency for New Technologies, Energy and Sustainable Economic Development