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Approches towards Sustainability in Midstream
and Downstream Rubber Industry: Life Cycle
Assessment (LCA) and Environmental
Labeling
Dr. Zairossani Mohd. Nor
Processing and Pollution Research Unit
MALAYSIAN RUBBER BOARD
Seminar on Sustainability of Rubber Industry
2
Global Environmental Awareness
Negate impacts of anthropogenic activities on environment:
• Climate change
Reduce greenhouse gas emission and air-borne pollutants
• Depleting natural resources
Reduce resource consumption (abiotic)
• Health–related issues
Reduce the use of hazardous substances
• Accumulating solid wastes
Reduce resource consumption and waste recycling
Approaches:
I. Ecodesign or design for environment
II. Cleaner production (waste minimization, energy
efficiency, GMP and MFCA)
III. Communication through ecolabelling
3
Drivers of Environmental Awareness - LCA
Europe - EU policies such as IPP, REACH, EuP, RoHS
- Directives for Promotion of Renewable Energy
- Green Public Procurement
Japan + Law for a Sound Material-Cycle Society
+ Green Procurement Policy in government sector
+ Product Green Promotion Program
USA * USEPA Product Stewardship Program
Clean Development Mechanism (CDM) – Certified Emission
Reduction (Kyoto Protocol) (2008-2012)
Conceptual Approach of Sustainability
The Dominant Model
Dependency of economic, social and environmental aspects
(sustainability pillars)
Economy
Social
Environment
Sustainable
Development
Sustainable Development - Industrial Ecology
Life Cycle Assessment LCA is an environmental management method for the
quantitative evaluation of material resources invested,the environmental burden and the environmental impacton the earth of a product or service through all stages ofits life cycle (Narita, 2004)
LCA assess the environmental aspects and potentialimpact of a product through;
Compiling an inventory data concerning inputs andoutputs of a product system
Evaluating the potential environmental impactassociated with those inputs and outputs
Interpreting the results of the inventory analysis andimpact assessment phases in relation to theobjectives of the study
5
LCA – ‘Cradle to Grave’ Evaluation of Products
Resource Manufacturing Use/Repair Disposal
Reuse
Recycling
Life Cycle Stages
Calculations of Environmental Burdens• Burden on atmosphere (SO2, CO2, NOx)
• Burden on water (BOD, COD, Nitrogen, Phophorous, Metals)
Impact Assessment of Environment• Global warming, water pollution, health effects, acidification,
eutrophication
Effects of LCA• Preservation of environment, environmentally-sound (eco) products,
environmental labels, design for environment (DfE), recycling society6
7
Natural Rubber Industry
Upstream
(Plantation)
Midstream
(Processing)
Downstream
(manufacturing)
Raw Materials
• latex
• cuplumps
• sheet rubbers
(RSS, ADS)
Processed Rubber
• block rubber (TSR)
• latex concentrate
• specialty rubbers
Rubber & Rubber-
based Products
• tyres
• gloves
• GRG/IRG
Environmental Impact of Rubber Industry
Air Pollution & Malodour Issue
Sludge production from rubber
Product manufacturing
( 6.0 million kg / yr)
Release of CO2, NO2 and methane
in processing and manufacturing
Effluent discharge from
rubber processing
(55 million liters / day)
Effluent discharge from
rubber product manufacturing
(30 million liters / day)
Area/Objective Applications
Decision making
(Internal)
• Design and development for process/product
• Purchasing
• Support for regulatory measures and policy
instruments
• Avoid transfer of environmental burdens (EIA)
Learning/exploration
(Internal)
• Characterization of production systems
• Optimization tool
• Selection of environmental performance
indicators
Communications
(External)
• LCA based eco-labeling (ISO 14025)
• Environmental product declarations
• Benchmarking
• Indicator of sustainability
LCA Applications
9
ISO 14000 Series and LCA
ISO 14000 is a series of environmental standards which provide structure and tool for managing the environmental aspects/impacts of the organization’s activities
Trends in environmental management:
- Emphasis on sustainable development
- Life cycle thinking and LCA
- Ecodesign
- Eco-labelling
- Green procurement / Green purchasing10
ISO Environmental Framework
Environmental
Management
System
(ISO 14001/4)
Environmental
Performance
Evaluation
(ISO 14030s
Environmental
Auditing
(ISO 14010s)
Design for
Environment
(ISO 14062)
Life Cycle
Assessment
(ISO 14040s)
Labelling &
Marketing
(ISO 14020s)
Organizational
Focus
(Cost)
Product
Focus
(Revenue)
Environmental Communications
ISO/TC 207
SC1
EMS
SC2
EA
SC3
EL
SC4
EPE
SC5
LCA
SC7
CC
TCG
11
ISO 14024 ISO 14021 ISO 14025
Type IIIenvironmentaldeclarations
(LCA)
Type IIself-declared
environmentalclaims
Type Ienvironmental
labelling(third party certification)
Programoperators,
environmentallabelling Type I
Marketingconsultants,authorities,
Lawyers, courtetc.
Programoperators,
environmentalproduct declaration
Type III
Different Concepts & Target Groups
Environmental Labelling: ISO 14020 Series
Elements of LCA
Direct applications
e.g. product development
marketing
ecolabelling
public policy making
Goal & scope
definition
InterpretationInventory
analysis
Impact
assessment
(ISO 14040)
13
Inventory Analysis
Is an account of all masses and energy inputs and outputs to the life cycle system
An objective, data based process of quantifying energy and raw materials requirements, air emissions, waterborne effluents, solid waste and other environmental release incurred throughout the life cycle of a product (Svoboda, 1995)
Two types of inventory data (foreground and
background)
14
Impact Assessment (LCIA)
15
Raw Material
Acquisition
Production
Use
Disposal
Emissions
to air
Emissions
to water
CO2 •
CH4 •
CFCs •
SOx •
NOx •
NH3 •
HCl •
VOC •
PO43- •
NO3 •
BOD •
Global warming
Ozone layer depletion
Acidification
Photo Oxidation
Eutrophication
Human toxicity
LCIAInventory
(e.g. emission/kg)
Impact
Category
Better
Products?
16
14 1.5 7.3
601
0
100
200
300
400
500
600
Glo
bal w
arm
ing
pote
ntai
l per
car
tyr
e (k
g
CO
2 eq
uiva
lent
)
Acquisition
of raw
material
Transport Production Use
GWP as an Impact Category for Production of
a Car Tyre
Source: Continental AG, Germany
17
Status of Environmentally - Friendly Tyres
Michelin
1. Michelin A2 Energy tyres (2006)
Reduce fuel cost by 6%, 20 – 40% increase in service life
Dunlop-Falken (Sumitomo)
1. ENASAVE ES 801 (2006)
Reduce rolling resistance by 30%, 70% petroleum-free
contents (44% in normal tyres)
2. ENASAVE 97 (2008)
Reduce rolling resistance by 35%, 97% petroleum-free
contents (44% in normal tyres)
LCA in Rubber Industry
• A right direction to achieve the common goal of emission reduction, waste reduction and adaptation of clean technology.
• Slowly gaining momentum as a solution to environmental problems especially in EU countries.
• Current focus more on LCA for car passenger tyre-based on European conditions
• ERTMA used LCA data as a basis for their product performance towards reducing the environmental impact.
19
Development of LCA for Block Rubber
Processing
Goals:
To establish the energy and material balance
for the production of 1200 kg (1 pallet) of
block rubber
To quantify the amount of CO2 emission as a
result of producing 1200 kg (1 pallet) of block
rubber
To quantify the carbon footprint of 1200 kg (1
pallet) production of block rubber
20
Scope of Study
Functional unit in this proposal will be the
production of 1200 kg (1 pallet) of block rubber.
All masses and emissions calculation in this
proposal will be based on the defines functional
unit.
Environmental Impact categories to be studied
Global warming (CO2)
Eutrophication (BOD, NO3, PO4-3)
22
Data and Assumptions for LCACriteria Data/Estimation
Capacity of plantation 400 trees/ha
Life span of trees 25 years
Average yield (dry) 1400kg/ha/year
CO2 sequestered 20606 kg/ha/year
CO2 sequestered/ton of rubber 14718 kg
Fertilizer used 1kg/tree/year or 409 kg/ha/year
Fertilizer run off from plantation 30%
1 liter of diesel Emits 2.68 kg of CO2
1 kWh electricity Emits 0.43 kg of CO2
Diesel consumption for a 3-ton lorry 5.4 km/L
24
Input-Output Table for Plantation
Input Quantity Unit Output Quantity Unit
CO2
Sequestered
by tree
14718 Kg Latex/Field
grade (dry)
1000 Kg
CO2
Sequestered
by soil
…….. Kg CO2 2.68 Kg
Fertilizer 292 Kg Nitrate 10.5 Kg
Transportation
(Diesel)
1 L Phosphate 10.5 Kg
25
Input-Output Table for Block Rubber Production
Input Quantity Unit Output Quantity Unit
Latex/Field
grade (dry)
1200 Kg Block
rubber
1200 Kg
Electricity 300 kWh CO2325 Kg
Diesel 72 L Amm.
Nitrogen
1.9 Kg
Water 32.4 M3 BOD 3.2 Kg
Chemicals
(HNS)
1.8 Kg COD 8.16 Kg
Chemicals
(Formic acid)
7.2 Kg SS 3.37 Kg
Transportation
(diesel)
1 L Total N 2.49 Kg
Total Solid 13.6 Kg
26
Summary of Carbon Auditing
Boundary CO2
Sequestered
CO2 Emitted
Plantation -17661.6 3.2
Block Rubber
Production
325.0
Total -17333.4
27
Overall worldwide rubber plantation of 9.1 million ha sequesters
261 million tonnes of CO2 from the atmosphere or 6.3%
absorption of the current rate of CO2 increase globally (MRB &
IRRDB)
Limitations of LCA
The nature of choices and assumptions made in LCA (e.g. system boundary setting, selection of data sources and impact categories) may be subjective
Models used for inventory analysis or to assess environmental impacts are limited by their assumptions, and may not be available for all potential impacts or applications
Results of LCA studies focused on global and regional may not be appropriate for local application
The accuracy of LCA studies may be limited by accessibility or availability of relevant data, or by data quality
29
30
Challenges in Implementing LCA and
CFP
• Synergistic mechanism of economic growth with
environmental and social considerations are not easy for
developing economies (technically and support industry)
• The export market demands that govern the environmental
and social aspects of a product or service
• Introducing LCA and CFP do not necessarily translate into
increase in business or profits
• LCA has been more technological focus while business-
decision support require economic considerations
31
Impact of LCA and CFP on Rubber
Producing Economies
Environmental related specifications are potential non-tariff
barrier
Supply chain-driven requirements is a main driver of
environmental requirements of products
Voluntary environmental requirements in marketplace can
become commercial imperatives
Environmental features of products shifting from niche
markets to mainstream markets that are eco-positioning their
corporate image