PVC Sustainability Tool User Manual (V1.1)
Contents
1. E Baseline PVC production Environmental Impacts Comparison E PVC production 1 8 O PVC production 2 7 E3 0 z Global warming Acidification potential Eutrophication Ozone layer Photochemical Human toxicity potential kg CO2 kg 502 eqJf u x potential kg depletion potential smog kg ethene potential kg DCB eqJf u x10 3 10 0 Phosphate eqiftu x kg R11 eqJfu x eqiftu x10M eqiftu x 1041 10M 1045 Impact categories Figure 29 Graph of all environmental impact data comparison 12 Sharing data between users Data and carbon footprint analyses can be shared between users via the menu option Share data By selecting the Export option from this menu a form is shown that allows the user to select an analysis that has already been saved see section 6 1 and then export it Figure 30 This action will create a new excel file entitled Share data xls in the 32 users default directory This file contains all of the analyses exported along with the database Select Analyses to export Flooring original study Pipe scenario 2 Pipes original study PYC granulate original study Windows original study Recycling White chips Recycling Jazz chips Recycling Jazz pulver PYC Compounding white chips Eq Export data Exit Figure 30 Data export form In order to import a previously created analysis the user selects2. 6 5 4 Defining waste use Waste use for any stage can be defined using the same procedure as for materials energy or packaging The user form is similar and is shown in figure 12 The procedure for waste is as follows 1 Select the required packaging type e g PVC Incineration from the drop down menu 2 Enter the amount of waste in the text box e g kg per f u 16 Select the data quality of the amount being used high medium low Include any relevant comments in the comments box Include the cost of waste disposal Click on the Update button ane Define waste for Windows manufacture Define waste Link waste Modify Database Waste stream Amount kg f u 001 mr Data quality for amount Low T Cost kg waste 9 Comments on amount used m Details kg COZ eq kg Year Location Source Data Quality y Comments Figure 12 Define waste user form 6 5 5 Linking the waste use to raw materials The waste use can be linked to raw materials use This function allows the user to automatically update the amount of raw materials used when the amount of waste at a particular stage is changed This feature is useful if a large number of raw materials are being used as it saves having to go back and update them if the waste amount changes To use this feature the user first clicks on the Link waste tab on the waste user form see Figure 13 17 Define waste for Windo
3. 14 85 Data quality for er br Low Update Cost MJ 6 40E 01 Comments on amount used Details kg COZ eq MJ Year Location Source Data Quality Comments on data set Figure 10 Define Energy user form The energy table on the screen will be updated with the relevant information and the carbon footprint shown 6 5 3 Defining packaging use Packaging use for any stage can be defined by clicking the Define Packaging button The associated user form is shown in figure 11 below The amount of packaging is defined as follows 1 Select the required packaging type e g Polyethylene film PE LD from the drop down menu 2 Enter the amount used in the text box 3 Select the data quality of the amount being used high medium low 15 4 Include any relevant comments in the comments box 5 Include the cost of the packaging per unit mass 6 Click on the Update button Define packaging use for Windows manufacture Define packaging Modify Database Packaging Polyethylene terephthalate Film PET Amount kgff u 9 02 IEG Dat lity F SE amount Medium v Cost kg 0 00E 00 Comments on amount used meea O Details kg COZ eq kg Year Location Source Data Quality Comments Exit Figure 11 Define Packaging user form The packaging table for the stage will now be populated Packaging types can be removed from the analysis by setting the mass to zero
4. AutoShapes x JO Alal 2 a gt Exit Figure 5 Stage details and Define Stage user form E View carhon Back to top level Define materials Define energy Define packaging Define waste footprinf a Define materials Modify Database Materials Stage Raw Materials i a Total carbon footprint for stage 24 51 kg CO eq f u Select Processing stage for E Total costs for stage 2 55 F u material use ji ay t kg F u R terial Amount C02 eq kg kg C02 eq Cost Ekg Cost f u mee unde mem prata kg f u raw material kg f u Ee idea Data quality for material amount gt Limestone 0 54 0 11 0 06 1 21 0 22 Cost Eka Methyl methacrylate MMA 0 57 6 83 3 89 2 00 0 38 Polyvinylchloride granulate Comments on amount used Suspension S PVC 7 34 2 74 20 11 0 65 1 59 Titanium dioxide TiO2 0 30 3 30E 05 9 90E 06 1 40 0 14 Zinc stearate 0 28 1 65 0 45 2 40 0 22 Ea Total 24 51 Total 2 55 kg CO ea fg Amount C02 eq kg MJ C02 eq Cost MJ j Year Energy type MJ f u energy kg f u energy Coster Total 0 00 Total 0 00 Location r 7 Source Packaging for raw Amount CO2 eq kg kg C02 eq Cost kg E A z Cost f u materials kg f u packaging kg f u packaging Data quality of a Total 0 00 Total 0 00 dataset Comments Amount COZ eq kg kg COZ eq Cost kg 7 Waste kg f u waste kg f
5. MANCHESTER y er The Universit of Manchest PVC Sustainability Tool User Manual V1 1 The University of Manchester October 2010 1 System requirements reen na nanaaaaara an annaaa 3 2 Tool development credits ai Sae Ear er 3 3 Acknowledgements se anitae sedan LEE DINE datagrid een DE adia a cassa Aida 3 4 ANModUCcion a Ss ad eae ad E aA PERO aa alain 4 5 PVC Sustainability Tool overview see aeee reene 4 6 Starting and building a new analysis renerne renerne 7 6 1 Define the system details eee LEE 7 6 2 Defining the processing stage NAMES a renerne rr rn rr rr nee 8 6 3 Defining the raw materials use ie eearerereeeacananeena 9 6 4 Defining transport rare acaaaneea ea terrer nnne eneen 10 6 5 Defining stage details eres 12 6 5 1 Defining material outputs rrenan 12 6 5 2 Defining energy Use ieee eieaa ee Te iiaa KENE N 14 6 5 3 Defining packaging use is rr REE ELLER LL ER 15 6 5 4 Defining waste use is ieeeeeeeeeaeeneaaacaaaaeeranaaaananea 16 6 5 5 Linking the waste use to raw materials rreren 17 T Data Display iriran anin se ocd taxi ie asas es a leet eden en o iA O Santee 20 7 1 Carbon footprint Gata aeeie e eeso oaa ere MS Aa eel ae eee 20 7 2 Value added data isnie iiine ged dante det eae dre d
6. Sags oo o Stage o Stage10 do Average Processing Medium Storage o Storage ransport stages Raw Materials gt Processing Windows manufacture se pO Transport stages o o Medium Figure 32 Part of data quality assessment screen 35 Appendix A Data quality criteria A1 1 General about LCA data quality According to PAS2050 the following data quality requirements should be considered when performing an LCA time related coverage geographical coverage technology coverage precision and accuracy completeness consistency reproducibility and sources of data primary or secondary Thus data quality assessment is a complex task as multiple aspects need to be considered including the context in which the data are used Enough information on the data is therefore fundamental to avoid their misinterpretation or misuse A1 2 Data quality assessment in the PVC sustainability tool The quality of data within the PVC sustainability tool can be defined by a user as High Medium or Low To help the user determine whether their data are of High Medium or Low quality a methodology specific to the PVC sustainability tool has been developed using the data quality criteria mentioned in the previous section The criteria used in the methodology are summarised in Table A1 Table A1 2 shows how these can be aggregated to arrive at an overall Data Quality Indicator DQI High Mediu
7. 11 12 Enter the estimated packing density of the material into the text box if not known leave as the default value of 1 The packing density is only important for low density products approx 300 kg m3 or less If a truck has been selected decide whether you want it to return home empty and if so select the check box Selecting empty return will increase the carbon footprint for a transport option by about 60 Define the cost of the trip per functional unit Select the data quality for the distance you have used high medium low Click the Update button The transport table will then be updated with information pertaining to the journey you have just described Information pertaining to Transport type distance mass transported carbon footprint for journey and total carbon footprint for the stage are all shown Back to top level Define transport Transport stage Raw Materials gt Processing Total carbon footprint for stage 0 02 kg CO eq f u Material transported Transport Type Distance km Ei d kg a ED gt ps 22t truck 0 18 1 05E 03 Empty return trip FALSE 22t truck 2 45 0 01 LSE gt Windows manufacture Zinc stearate gt Windows manufacture Methyl methacrylate MMA gt Windows manufacture Titanium dioxide TiO2 gt Windows manufacture 22t truck 0 09 5 35E 04 22t truck 1 11E 03 22t truck 5
8. Medium High High 3 Low High Medium 2 High Medium Medium 2 Medium Medium Medium 2 Low Medium Medium 2 High Low Medium 2 Medium Low Low 1 Low Low Low 1 Note that the datasets already available in the tool have a predefined DQI so that the user only needs to define the quality of their own datasets Once the data quality indicators have been calculated for each sub system a weighted approach is then applied for assessing the overall data quality of the whole system based on the percentage contribution of each life cycle stage to the total carbon footprint The overall data quality for the whole system is therefore calculated as DO cs E SLO DOS n l m 1 where DQcr overall data quality of the system Ih percentage contribution of each life cycle stage to the total carbon footprint DQSm data quality 1 2 or 3 for sub system m 38 For the purposes of the analysis in the PVC sustainability tool the following ranges have been adopted for the overall data quality of the whole system Low data quality DQcr 100 166 Medium data quality DQcr 167 233 and High overall data quality DQcr 234 300 39
9. 4 62 Value of final product Total value added Figure 18 Value added data display for each stage The value added data is also displayed in a graph for each stage Both costs and value are shown This can be accessed by clicking on the View graph button Figure 19 shows an example of a graph The View missing data button can be clicked on in order to be taken to a table of data for which there is currently no value data ES Microsoft Excel PVC sustainability tool fi e Window Comparison PVC study Share HEL Type a question for he X data PvCHelp Help Adobe PDF Reply with Changes End Review B Bl Backto value added analysis Value added per stage 1400 1200 1000 800 600 E Costs 400 E Value 200 Value added 0 200 400 4 600 Be af af P E A 2 Ed Fa a FA E E E oF oh amp x ee Le Figure 19 Value added graph 23 8 Modifying the database 8 1 Creating a new database record It is probable that during the course of an analysis the user will need to create a new database record This can be done for any of the following materials energy packaging waste transport New database records can be created by e selecting the Modify Database tab on the appropriate user form see Figure 20 below for materials example e clicking the Crea
10. 62E 04 Select material to define transport for Limestone gt Windows manufacture Methyl methacrylate MMA gt Windows manufacture Polyvinylchloride granulate Suspension S PYC gt Windows manufacture Titanium dioxide TiO2 gt Windows manufacture Zinc stearate gt Windows manufacture Exit Figure 7 View of transport stage and user form for selecting transport stream A journey can be removed at any time by setting the distance travelled to zero 11 6 5 Defining stage details The details of the process stages and the storage and use stages can now be defined by entering each individual process stage in tum see section 3 2 above for how to navigate 6 5 1 Defining material outputs Material outputs can be defined from any stage apart from the Use stage It is necessary to create a material output from a stage for two reasons 1 Transport can only be defined if there is a material flow between stages 2 Each stage is mass balanced Material outputs show up as a mass input at its destination stage Material outputs are named by the user and have a mass associated with them They are created as follows 1 Click on the Define stage button to show the appropriate user form Select the Material outputs tab Type the name of the output flow into the drop down box provided the material can be selected later on and its mass changed Select the destination stage for the material Add the mass of
11. available for each individual stage apart from transport stages Carbon footprint for Windows manufacture kg CO2 eq functional unit Energy Direct Packaging Waste Total emissions Figure 17 Carbon footprint for individual process stage 7 2 Value added data Value added data is displayed throughout the tool in blue The units are expressed in pounds per functional unit e The total value added during the analysis is shown in the life cycle view at the bottom of the screen e Inthe life cycle view the value added for each stage is shown above the relevant stage box and e Inthe Processing section the value added for each processing stage is shown above the relevant box and the total carbon footprint for processing is shown at the top of the screen The value added summary is also displayed in a tabular form and can be accessed by clicking the View value added analysis on the top sheet Figure 18 shows the value added data displayed for each stage as well as the total value added during the whole analysis 22 Ei File Window Comparison P Cstudy Sharedata Help E s ee Warning some value data are missing or are zero Back to top level View graph View missing data Value of stage Value added at 0 27 2 01 Embossing 0 27 4 35 J tages tageb tage taged tageg tage10 torage ransport eating and Cooling om oo om Doom 0 00 am 1 40E 0 Nal 03d Mixing 2 28
12. data Source of data Measured and or Modelled using generic Mainly sourced data from LCA databases some data derived using expert knowledge from literature and or estimated and or derived using expert knowledge Completeness All inputs and outputs Majority of relevant Some relevant of data considered inputs and outputs inputs and outputs considered considered or known Reproducibility Completely Partly Not reproducible reliability reproducible reliable reproducible reliable not known consistency of consistent consistent data Table A1 2 Aggregating individual Data Quality Indicators DQI to arrive at an overall DQI High Medium or Low High quality Medium Low quality Weighting quality Example data for each Max score for Max score for quality Data quality criterion ona each criterion 3 Max score for each criterion 1 assessment criteria scale 1 10 each criterion 2 Age 2 3 2 1 1 Low Geographical 1 3 2 1 3 High origin Source 3 3 2 1 2 Medium Completeness 2 3 2 1 3 High Reproducibility 2 3 2 1 1 Low reliability consistency Maximum 30 max score 20 max score 10 max score 19 score overall score Overall score for Overall score for Overall score for Data quality High in the Medium in the Low in the indicator range 21 30 range 11 20 range 1 10 Medium The sum of all weights is 10 37 NB The over
13. ails modified Database records that are not user defined i e that come as standard with the software can not have their properties modified 8 3 Deleting a database item User defined database records can be deleted by selecting the item in the listbox see figure 20 and clicking on Delete item The user will be asked if they are sure they want to delete the record in question Database records that are in current use in the LCA can not be deleted Database records that are not user defined i e that come as standard with the software cannot be deleted 9 Loading Saving data Analyses can be loaded saved deleted using the PVC study menu item at the top of the screen Figure 23 below shows the menu options available This can be done if it is necessary to save the data in order to start a new analysis or to load a previous analysis 26 PYC study Share data Load PYC study Help Save PYC study Start new PYC study J Delete PYC study Figure 23 PVC study menu options 9 1 Saving an analysis In order to save a study the user selects Save PVC Study from the PVC Study menu option and is then asked to enter a unique name into a drop down box or select a previously saved study to over write it Note Saving a study saves the data to a new worksheet but it does not save the workbook To do this the user must use the Excel File Save menu It is recommended that the user saves the file on a regular basis 9 2 Load
14. all score of 19 has been calculated in the following way Overall score 2 1 1 3 3 2 2 3 2 1 19 Therefore the overall data quality indicator Medium It should be noted that the overall data quality will depend on both the quality of the particular datasets used by the user as well as on the confidence the user places on the quantity amount of materials energy etc they are defining for each sub system For example the quality of the background dataset for UK electricity mix and the related carbon footprint may be High however the user may not be confident in the data related to the amount of electricity used in a particular sub system so that the quality of this datum may be Medium or Low In this case since the data quality for the set is already defined as high the user will only need to specify the quality for the quantity amount and the tool will calculate the overall data quality for that particular sub system The process is repeated for each sub system The approach used for calculating DQI for a sub system is shown in Table A1 3 Note that the quantity amount is considered more important here than the quality of the dataset Table A1 3 Aggregating the Data Quality Indicators DQI to arrive at an overall DQI for a each sub system DQI for user defined DQI for the amount quantity Data quality of each sub dataset entered in the PVC system DQS sustainability tool by the user High High High 3
15. ant text box e g Windows manufacture Enter any relevant comments in the Comments text box Click Update or e O A a Once this is done the tool will update all instances of the stage name in the analysis 6 3 Defining the raw materials use All raw materials usage needs to be defined in the Raw Materials section of the tool This can be accessed by clicking on the relevant box in the life cycle view A view of this level is shown in Figure 6 It can be seen that there are four tables representing materials packaging energy and waste The amount of each of these can be modified by clicking on the appropriate button at the top of the screen In order to add a raw material to the analysis the following procedure is used 1 Click on the Define Materials button 2 Select the required material from the first drop down list 3 Select the required processing stage from the second drop down list 4 Add the amount of material required to the textbox 5 Select the data quality for the amount used high medium low see appendix 1 for a description of how the data quality is calculated for the system 6 Add the cost of the material in pounds for the purposes of the value added analysis 7 Add any comments that are appropriate to this instance of material use 8 Click the Update button Backto Define View carbon eget Define stage Define energy gamle Define waste Fee BE Stage Windows manufacture Total carbon footprint for s
16. ased by 0 1 kg If multiple materials are linked to a waste stream then the amounts are adjusted in proportion to the ratio of their use For instance If three materials are linked to one waste stream Landfill Municipal 1 kg Material 1 4 kg Material 2 4 kg Material 3 2 kg Then increasing the amount of waste would have the following effect Landfill Municipal 2 kg 19 Material 1 4 kg 0 4 kg 4 4kg Material 2 4 kg 0 4 kg 4 4kg Material 3 2 kg 0 2 kg 2 2kg 7 Data Display 7 1 Carbon footprint data Carbon footprint data is displayed plainly throughout the tool and is always shown in red The units are always mass per functional unit f u where mass is the current operating unit e g kg tonne g A The total carbon footprint for the analysis is shown in the life cycle view at the bottom of the screen In the life cycle view the carbon footprint for each stage is shown above the relevant stage box In the Processing section the carbon footprint for each processing stage is shown above the relevant box and the total carbon footprint for processing is shown at the top of the screen In each individual stage the total carbon footprint is shown at the top of the screen In each stage the components of the carbon footprint are shown in the relevant tables and The carbon footprint associated with a particular material energy type packaging type waste type or transport type is displayed
17. e 2 6 1 Define the system details The system details user form can be activated by clicking on the Enter System Details button at the top of the screen in the life cycle view The user form is shown in Figure 3 In order to proceed with the analysis the user must define a functional unit This is the mass of the product to which the carbon footprint will be attributed in this case 3 kg The name of the product can also be defined in this case Windows as well as information pertaining to the data e g date collected estimated quality source although this is not compulsory System Details Name PYC Flooring to cover 1m2 Functional unit 3 kg Mass unit kg Energy unit MI Distance unit Currency unit Pound vw Exchange rate per Data collected yr 2009 ilk Data source Confidential System last 07 09 2009 updated date tosi Author Notes Functional unit PYC Flooring 3 kg of PYC Flooring to cover 1m2 of Floor System boundaries cradle to gate Assumptions The total energy consumption is equally distributed across the production stages to preserve confidentiality OK Cancel Figure 3 System Details user form Mass energy distance and currency units of operation can also be defined The default values for these are tonne kWh km and respectively The units can be changed at any point during the analysis If using a currency other than an exchange rat
18. e should be supplied to the textbox This enables the user to switch between currency types during the analysis The system details can be updated by clicking on the OK button after which the whole system takes a short while to update 6 2 Defining the processing stage names It is a good idea to name the process stages before defining the raw materials use There are ten processing stages available in the current version of the tool The overview of these is shown in Figure 4 This stage can be accessed by clicking on the Processing box in the life cycle view Microsoft Excel PVC sustainability tool xls El Ele Window Comparison PYC study Sharedata PYCHelp Help View carbon Back to top level farias pre Stage Processing Total carbon footprint for stage 1 57 kg CO eq if u Total value added for stage 7 93 Elf u 2 01 3 64 4 35 8 73 0 00 0 41 0 38 0 41 0 38 0 00 Figure 4 Overview of Processing The carbon footprint for each stage is shown in red and the value added in blue The above example contains only one stage Windows manufacture The rest contain no data so are not defined When the tool is first loaded all the stage names are called Stage1 Stage2 etc They can be modified at any point during the analysis as follows Click on the stage to be modified to see its details Click on the Define Stage button at the top of the screen Enter the name of the stage in the relev
19. ekret re E ad radio 22 8 Modifying the database ccc csecceceeeeceeeeeeeeeeeeceeeaeeeeseceeeeaeeeeeeessecuseeeeesssnseneeeeees 24 8 1 Creating a new database record eretas 24 8 2 Modifying an existing database item ese 25 8 3 Deleting a database item erre nere 26 9 L ading Saving data sisissoss resina pontes nere ut cora pa eerie Aa EE Eada 26 9 1 Saving an analysis renere nana 27 9 2 Loading an analysis ea te n ie tenet Ea tatararaa dahk baaada dTa iadddn 27 9 3 Starting New StUGY acer FEE rer AE E ERE ERRE E AEE AER EEEE 28 9 4 Deleting an analySiS ienet in aa iridia a a ia ea e aE Ari 28 10 Examining other environmental impacts ssssneeeeererreren ea 28 11 D ta compafis ons rr enhe ea te eead a lobes eee 30 11 1 Carbon footprint comparison sssseeeeeeeerere ese R EL rerne nen 30 11 2 Other impact comparison renerne ennen rr E ELLER LEE 31 12 Sharing data between users eee rn renere ELLEN Er 32 13 Data quality assessment reeniri aeia i ti aa a ere i ie 34 Appendix A Data quality criteria ennen LER 36 A1 1 General about LCA data quality eae 36 A1 2 Data quality assessment in the PVC sustainability 1001 36 1 System requirements The PVC Sustainability Tool was designed and built using the English version of Microsoft Excel 2003 for Windows XP It may not run prope
20. following five impact categories e Acidification potential e Eutrophication potential e Ozone depletion potential e Photochemical ozone creation potential and e Human toxicity potential If the user has created their own data sets at any point then they will see a message in red font stating Warning Some of the data used in the analysis are incomplete To complete click the Modify user defined data button In the latter case it is necessary for the user to supply data for the new data sets they have created before the results for these extra impact categories can be considered to be complete To do this the user clicks on the Modify user defined data button This brings up the form as shown in Figure 25 28 To define the environmental impacts select the item of interest below and click the button Define impacts If no items are shown below then all the impacts have been defined Define impacts To change the previously defined impacts select the item of interest and press the Modify impacts button Diesel PVC Waste Modify impacts Fines from ESS to landfill vinyl chloride CM Chloroethane Waste heat NG offset PYC fines Exit Figure 25 Modify user data for other impact categories form The top text box shows all of the data sets for which other impact data are missing The bottom text box shows all of the user defined data sets for which impact data can be modified To specify m
21. in a greyed out text box on the relevant user form when it is displayed e g in Figure 11 above the carbon footprint for Landfill Municipal Waste is 0 715 kg CO2 equivalent per kg of waste graphical representation of carbon footprint data is available at various points throughout the tool Graphs can be viewed by clicking the View graph of carbon footprint button at the top of the page Figure 15 below shows the graph of the total carbon footprint available in the life cycle view 20 EE iodo Summary of Carbon Footprint 12 00 124 10 00 8 00 6 00 4 00 kg CO2 eq functional unit 2 00 5 57E 03 0 00 Raw materials Processing Storage Transport Total View graph View graph View graph View graph View graph Figure 15 Graphical view of total carbon footprint Clicking on one of the buttons below each bar on the graph will bring up another graph with a breakdown of the carbon footprint for that particular stage For instance clicking the button below Processing shows the carbon footprint for each of the processing stages Figure 16 Back to main chart 3 50 3 00 2 50 2 00 1 50 1 00 kg CO2 eq functional unit 0 50 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 0 00 T T T T T T T T T T e 4 2 A 2 N amp es E E e SB Sal amp S KS Chart Area Figure 16 Carbon footprint for Processing stages 21 Graphs are also
22. information from the current analysis will be added to the appropriate note if all four tables are populated by data the user will be given a choice as to where they would like new comparison added The user can then go back to the analysis change it and then come back to the data comparison sheet and add the new analysis in order to compare the two They could also go back load a previously created analysis and then compare this tables of data are not cleared on using the Load CF study function The tables can be cleared individually by clicking on the Clear comparison data button at the bottom of each table A graphical comparison of the data in the tables can be viewed by clicking on the View graphs button at the top of the sheet 30 Back to top level analysis Add current View graphs Functional unit Baseline Analysis 3 kg Do kg C02 e aw Materials CT Ss et 3k Doo Po kg C2 G F Stage2 Stage3 CT CS tage Mi 00 tage4 tages Em tage tage 00 ek Stage8 E Em O tage9 Stage10 oo Storage CC SS Sat 22 Do aw Materials irect GHG emissions fu indows manufacture Stage10 TO se 00 potas Oa FSC ee Energy To o 29 Direct GHG emissions 000 Do Toa am Remove scenario from analysis Figure 27 Partial View of the carbon footprint data comparison sheet ransport Total Doo ackaging ransport Waste T
23. ing an analysis A previous analysis can be loaded by selecting Load PVC Study from the PVC Study menu option A listbox will appear with the names of previously created analyses that the user can select from see Figure 24 below Note loading a previous analysis will overwrite any data currently being used Users are advised to save their analysis before loading another one Select LCA to open Blood bags original stud Flooring original stud Pipe scenario 2 Pipes original study PYC granulate original study Windows original study Recycling White chips Recycling Jazz chips OK Cancel Figure 24 Load LCA user form 27 9 3 Starting new study The current study can be re started at any time by selecting the Start new PVC study menu item from the PVC Study menu The user will be asked if they are sure they want to reset and will then be given the option of saving the data first as in 6 1 above 9 4 Deleting an analysis Analyses that have been saved can be deleted at any time by selecting Delete PVC study from the PVC Study menu 10 Examining other environmental impacts As well as examining the carbon footprint for a system other environmental impacts can be examined This information can be seen by clicking on the View other environmental impacts button at the top of the screen in the life cycle view of the tool When this is done the user is taken to a new sheet showing graphs for the
24. issing data the user clicks on the Define impact data button to the right of the top text box after selecting a data set To modify existing data the user clicks on the Define impact data to the right of the bottom text box after selecting a data set Both buttons yield the same user form Figure 26 This form allows the user to specify the impact data for a specific data set by filling in the text boxes and clicking the Update data button 29 Impact data for PVC Waste Enter LCA data for the impact categories listed below Acidification potential kg sulphur dioxide eq fkg Eutrophication potential kg phosphate eq kg Ozone layer depletion potential potential kg R11 eg kg Photochemical ozone creation potential kg ethene eq kg Human toxicity potential kg dichlorobenzene eq kg Update data Exit Figure 26 Define impact data user form Uk 11 Data comparison Data for up to four analyses can be compared using the data comparison feature This can be accessed by clicking on the Comparison menu at the top of the top sheet The user can select between comparing the carbon footprint only or all of the environmental impacts 11 1 Carbon footprint comparison Selecting Carbon footprint takes the user to a new sheet Figure 27 The first table is always taken up with data for the baseline analysis for the PVC related process in question If the user clicks on the Add current analysis buttons then the
25. m or Low For these purposes each data quality criterion is assigned a weight of importance on a scale of 1 10 For example as shown in Table A1 1 Age of data has the weight of 2 being twice as important as the geographical origin of data Each data quality indicator is assigned an arbitrary maximum score for each criterion e g the High indicator has a score of 3 Medium has 2 and Low has a score of 1 see Table A1 2 Applying the weights of importance for each criterion and its maximum score for the respective quality indicators the maximum score for each quality indicator is 30 for High 20 for Medium and 10 for Low For the purposes of the analysis in the PVC sustainability tool the following score ranges have been adopted for the data quality assessment Low data quality score in the range of 1 10 Medium data quality score in the range of 11 20 and High data quality score range of 21 30 36 An example shown in Table A1 2 shows an overall score of 19 indicating Medium data quality noting that the overall score for Medium quality is between 11 20 Table A1 1 Matrix of Data Quality Indicators DQI for the PVC sustainability tool modelled based on specific data e g the company data or from suppliers Data quality Data quality indicators criteria High Medium Low Age of data lt 5 years 5 10 years gt 10 Geographical Specific Partly specific Generic average origin of
26. otal 112 11 2 Other impact comparison Selecting All impacts takes the user to a new sheet Figure 28 Addition and clearing of data is done in the same way as when comparing the carbon footprints section 8 1 When the data are cleared from the tables on this worksheet the default values are set back to 0 The data is plotted on a bar graph fig 29 without causing stability issues The graph can be accessed by clicking the View graph button The axis on the graph is automatically scaled 31 Add current E Back to top level len View graphs Baseline analysis Functional unit Analysis 1 Functional unit Windows 3 kg Environmental impact Value Environmental impact Value Global warming potential kg 1 507573025 Global warming potential kg COZ eq f u x10 1 i CO2 eq f u x10 1 Acidification potential kg 502 Acidification potential kg 502 5 375220515 eg f u x 1072 eq f u x 1072 Eutrophication potential kg Eutrophication potential kg Phosphate eq f u x 1073 KEA Phosphate eq f u x 1073 Ozone layer depletion potential Ozone layer depletion potential kg R11 equ x 107 TaS Sn kg R11 eg 4tu x 107 o SENSE 4 174354297 Photochemical smog kg q fu Hurnan toxicity potential kg Human toxicity potential kg DCB eg u x 1041 caida DCB eq f u x 1051 Remove scenario 1 from analysis Figure 28 Partial View of the environmental impacts data comparison sheet
27. rly on non English operating systems or on older versions of Excel or Windows The tool is designed for use on PCs and is not suitable for use on Mac computers Please note that depending on the speed of your computer some operations may take longer time to complete Normally the hour glass will indicate that the system is busy If it appears that there is no response after clicking on an option or action button or the cursor does not turn into the hour glass please wait a few seconds as the system is busy and may take some time to complete the action 2 Tool development credits The PVC Sustainability Tool has been developed by a research group at The University of Manchester led by Professor Adisa Azapagic The following researchers were involved in the development of the tool e Dr Anthony Morgan software development e Dr Heinz Stichnothe methodology development and case studies and e Dr Haruna Gujba case studies For further information contact adisa azapagic manchester ac uk 3 Acknowledgements This tool has been developed as part of the EPSRC funded project Improving Sustainability of PVC through Novel Materials Processes and Life Cycle Methodologies EP D505372 2 This funding is gratefully acknowledged The support of the project partners is also gratefully acknowledged in particular e Ineos ChlorVinyls Dr Jason Leadbitter and Roger Mottram e Loughborough University Prof Bryan Brooks Prof Marianne Gilbe
28. rt and Dr Noreen Thomas e ECOPLAS Bob Bittlestone and Steve Smith and e Polyflor Mike Minett and John Whitesmith 4 Introduction The PVC sustainability tool allows quick and easy assessment of environmental and economic sustainability of PVC products and processes It takes a life cycle approach and it enables estimation of the following environmental impacts Global warming potential a k a carbon footprint Acidification potential Eutrophication potential Ozone layer depletion potential e Photochemical smog e Human toxicity potential Economic sustainability assessment is related to the estimation of value added along the PVC supply chains The tool has been developed with the following objectives in mind e to avoid the need to use complex LCA software to calculate environmental impacts e to enable non expert users to calculate environmental impacts e to allow the user to estimate quickly and easily environmental impacts for a number of different PVC related products and processes following the 80 20 rule 80 of the result with 20 of the effort e to allow the user to identify environmental hot spots and identify improvement opportunities e to reduce the data collection effort by providing databases on materials energy transport packaging and waste and e to present data in a clear and easy to understand way 5 PVC Sustainability Tool overview The tool has been developed in Microsoft Excel It comes wi
29. s by accident then this option will take them back again without changing any information The Start new analysis button takes the user to a blank analysis so that they can start from scratch ES Microsoft Excel PVC sustainability tool ial Ele Window Comparison PVC study Sharedata PVC Help Help Adobe PDF Type a question for heh P X it ta casa 7 By 83 SYS Reply with Changes End Review gt to current analysis Start new analysis Select PVC Analysis This PVC sustainability tool enables you to carry out LCA and value added analyses of PVC processes and products Please click on one of the options below Depending on the speed of your computer this may take a few moments to upload PVC processes PVC Products dobe Acrobat Ej PVC tool user g ES Microsoft Excel CEEE 20 54 Figure 1 Start up screen of PVC sustainability tool Figure 2 shows the top level layout of the tool This represents a map of a typical product life cycle and includes the following stages e Raw materials e Processing e Storage e Use e Transport and e Waste The user can access any of these stages by clicking on the relevant box The subsequent levels allow the user to modify information contained at these levels this is described in more detail later on The Excel menu bars and toolbars are largely disabled for the sake of clarity although the user can still make use of the in built excel File Sa
30. ta sets the user can specify the data quality when they create it The data quality for the amount of material energy or travel distance specified by the user has to be specified each time the user adds a new datum to the analysis The user is required to make a judgment as to how reliable their data are For instance if a transport distance is known then the user might choose high quality of data however if the distance is only guessed at or generic then the data quality for this datum will be low The data quality assessment calculation is made by weighting each data point by its contribution to the carbon footprint A full description of the data quality model is given in appendix A Clicking on the View data quality assessment button at the top of the screen in the life cycle view of the tool brings up the data quality assessment sheet Figure 32 This shows the overall data quality for the analysis as well as the data quality for each individual stage 34 E Microsoft Excel PVC sustainability tool xls iad File Edit view Insert Format Tools Data Window Comparison PvCstudy Sharedata Help RW a MENTE OCU A Oe MES eee aC en eh eee TT j Arial 110 B C39 Ev Graphs A332 Back to top level Overall data quality Medium Data quality by stage Data quality Raw materials Medium P En co Processing stages J o Z O Stage3 medium Staged OL Stages Sags oo o Stage do RER Ol RER G
31. tage 9 04 kg CO eq if u Total value added at stage 211 05 Hu are Sas Cost kg raw i Total mass in materials Material Packaging inputs Amount kg material Cost f u packaging ka 9 03 Limestone 0 54 121 0 65 Total mass out materials 9 03 waste kg Methyl methacrylate MMA 0 57 2 00 1 14 Mass balance kg 0 00 Polyvinylchlorid lat Suspension S PVC as 7 34 0 65 4 77 Define stage Windows manufacture Titanium dioxide TiO2 0 30 1 40 0 42 P Snesere 028 240 0 66 Details Material output Direct GHG emissions All emissions Total 9 03 Total 7 65 Stage name 7 Windows manufacture Energy type Amount COZ eq kg MJ CO2 eq Cost MJ Cost f u MJ u energy kg f u energy Comments Electricity UK grid 44 55 0 19 8 27 0 14 6 24 Heat from natural gas 10 71 0 06 0 68 6 00E 03 0 06 Value of windiow frame is an estimate Total 8 95 Total 6 30 A ig Amount C02 eq kg kg C02 eq Direct emisions kg fu GHG kg u Total 0 00 r Amount C02 eq kg kg CO2 eq Cost kg j Rackagingitype kg f u packaging kg f u packaging Goat i Total 0 00 Total 0 00 Amount C02 eq kg kg C02 eq Cost kg f Waste kg f u waste kg f u waste Cost Efn Incineration PVC 0 03 2 96 0 09 0 00 0 00 Total 0 09 Total 0 00 Update t Draw l
32. te new item button e filling in the appropriate fields in the resulting user form see Figure 21 It is not possible to create an item with a name that already exists in the database Define raw materials Define materials Modify Database Select item to modify PYC Waste PYC Fines Delete item Create new item Figure 20 Modify database tab on Raw Materials user form Once created the item will be shown in the list of user defined items in the listbox and will be available to select from the drop down list in the appropriate list box e g raw materials energy etc 24 Create new database record Details Name CO2 eq kgjkg Year Location Source Data Quality d Comments Update database Cancel Figure 21 Create new database record form 8 2 Modifying an existing database item Any database records created by the user can be subsequently modified by selecting the item in the listbox see Figure 21 above and clicking on Modify Details This will show the existing details of the record see Figure 22 below 25 Modify database record Details Name fpvcfines cozeatkoika os Year 2009 Location Global Source Man Uni Data Quality Low Comments Landfill of 24C fines from electro static precipitator Update database Cancel Figure 22 Modify details for an existing database item Database records that are in current use in the LCA can not have their det
33. th a range of case studies and databases The case studies include PVC processes e PVC production e PVC recycling white chips jazz chips jazz pulver and e PVC compounding PVC products e Blood bags e Windows steel and glass fibre reinforced e Pipes and e Flooring The databases comprise e Materials Energy Transport Packaging and Waste management The worksheets in the tool are locked and are not accessible to the user This keeps the tool relatively safe as the database and links between cells cannot be modified accidentally Information can be entered into the tool via user forms that are activated by clicking buttons at the top of worksheets The user can navigate around the tool using the links provided When the tool is started the start up screen for the PVC tool is shown Figure 1 The user is given a number of options related to different case studies If the user clicks on one of these options they will be taken to the life cycle layout of the base case for the analysis they have selected Base cases have been constructed for each option from data supplied by the PVC industry as well as other publicly available sources The user can then modify the analysis to their own specifications The user may also select the Go to current analysis option This will take the user to the last analysis that was being examined If the user has come back to the start up screen at some point during the analysi
34. the Share data Import menu item This then prompts the user to locate the previously created Share data xls file in the desired directory Once this is done the user will be offered a choice of saved analyses to import multiple analyses can be selected Figure 31 Select data to import Windows original study Exit Figure 31 Data import form Selecting one or more analyses from the list and clicking Import data will import the selected analyses to the tool and update the database with any missing items Imported analyses can then be examined using the Load PVC Study menu item section 6 2 Note In order for the import export function to work the PVC sustainability tool must be the first and only excel workbook open It must not be renamed from PVC sustainability tool xis The Share data xls file must not be renamed 33 13 Data quality assessment Throughout the tool users are required to specify the data quality for the information they are inputting This takes two forms firstly the data quality of the data set and secondly the data quality for the amount being specified Data quality within the tool is always expressed as either high medium or low quality The data quality for the data sets is specified when they are created and is not subject to alteration during the analysis Data quality of the data sets supplied within the tool will invariably be high as they are from a trusted source For user defined da
35. the material to the text box Add the value of the material in pounds Click the Update button GEN OD OL EB Once a mass output has been created it will show up in the relevant transport stage as well as in the material inputs table of the appropriate stage processing storage or use 12 Define transport 22t truck Figure 8 Define Transport user form 13 Define stage Windows manufacture Details Material output Direct GHG emissions All emissions Modify existing output stream or create new stream Output PVC Window X Destination Amount kgjf u Product value kg 6 00E 00 Update Figure 9 Material output tab on Define stage user form 6 5 2 Defining energy use Energy use for any stage can be defined by clicking the Define Energy button The associated user form is shown in figure 10 The amount of energy is defined as follows 1 Select the required energy type e g Electricity from UK grid from the drop down menu 2 Enter the amount used in the text box NB make sure the correct units are being employed MJ in this case Select the data quality of the amount being used high medium low Include any relevant comments in the comments box Include the cost of energy per unit Click on the Update button o En E Go 14 Define energy use for Windows manufacture Define energy Modify Database Energy Amount MI F u Electricity UK grid
36. u waste Costu Total 0 00 Total 0 00 Figure 6 Raw materials stage with Define raw materials user form The Raw material table on the screen will automatically show the material name the amount used the carbon footprint associated with it and its destination Other materials can be added in the same way If a new material needs to be added to the database then this can be done through the Modify Database tab This is discussed in more detail in section 4 The total carbon footprint for the stage can be seen at the top of the screen in red The amount of material being used can be updated at any time or can be removed completely from the analysis by setting its usage to zero 6 4 Defining transport Transport links can be defined when there is a material to be transported between stages In order to define transport the following procedure should be used 1 Click on the relevant transport link 2 On the transport stage screen click the Define Transport button 3 A user form will appear asking the user to select material stream to transport see Figure 6 4 Select the required stream from the list box e g Zinc Stearate gt Windows manufacture 5 Click on Define Transport The Define Transport user form will then be shown see figure 8 6 Select the type of transport from the drop down menu e g 40 t truck 7 Enter the distance travelled into the text box note the units required 10 10
37. ve functions to save the tool at any point during the analysis Several menu options specific to the tool have been added Comparison PVC Study and Share data The function of these is described in sections 8 6 and 9 respectively The PVC help menu contains the manual as well as software development credits The carbon footprint for each stage is shown in red and the value added in blue E Microsoft Excel PVC_sustainability_tool xls 169 File Window Comparison PVC study Sharedata PVCHelp Help Back to PVC Enter system View carbon View data quality ver other View value added overview details footprint graph assessment environmental analysis impacts Functional unit f u PVC Flooring to cover 1m2 3 kg 2 67 7 93 1 40E 03 3 31 1 57 1 86E 03 0 00 0 02 0 01 0 00 Transport Transport 0 00 0 00 0 00 Transport Transport Transport 0 00 0 00 0 00 0 00 0 00E 00 Waste Management Key Total carbon footprint 4 92 kg Co eq if u Carbon footprint kg CO2 eq f u Total value added 5 25 fu Value Added f u Warning some value data are missing or are zero Figure 2 Life cycle view in the PVC Sustainability Tool 6 Starting and building a new analysis To start a new analysis the user can click on Start New Analysis from the start up screen Figure 1 and will be taken to the life cycle view Figur
38. ws manufacture Define waste Link waste Modify Database Modify material links Flows currently linked to selected waste stream Figure 13 Link waste tab Two text boxes are shown on the form The top box shows the list of waste streams used at this stage of the analysis that can be linked to materials used at that stage the bottom box shows the list of materials that are currently linked In order to link a material the user should click on the Modify material links button This will bring up a separate user form that allows the user to create and remove links using the appropriate buttons Figure 14 18 Create waste link to materials Raw materials used at this stage MEO errei Methyl methacrylate MMA Polyvinylchloride granulate Suspension 5 P C Titanium dioxide TIOZ Zinc stearate Create link Remove link Existing material links For Incineration P C Exit Figure 14 Create delete links form The top box shows raw materials used at this stage and the bottom box shows the existing material links for the waste stream selected The user will not initially see any effects of material linking However if the amount of waste being used is changed then the raw materials linked to it will be updated to reflect that change For instance if the amount of waste at this stage was 0 1 kg when the material was linked and it was increased to 0 2 kg the amount of raw material would be incre
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