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Introduction and MethodologyGeneral
Introduction:
The approach of this project is to carry out two iterations. The aim of first iteration is to get an overview of resource consumptions and the environmental impacts of manufacturing, using and disposing of the product based on assessable data and assumptions. The aim of the second iteration is to investigate those parts of the hydraulic product system that in the first iteration were found to be important. Based on the results of the second iteration it may be possible to identify the parameters in the stage(s) that should be investigated in the further studies. The recommendations for further investigations are based on: the highest impact on the environment, the largest consumptions of resources and the largest human uncertainty in combination with large impacts. The main objective of this study is to assess the environmental impact potentials, energy consumptions, and the resource consumptions throughout the entire lifespan of the hydraulic product by means of a literature survey, Sauer-Danfoss literature, questionnaires with externally involved companies and other related information sources. Furthermore the objective is to prepare an environmental diagnosis report on the most significant impact potentials and resources found, by integrating technical and ecological aspects in the optimization of the production, product design and product marketing in a life cycle perspective of the hydraulic product system.
Sauer-Danfoss is an international company with three main
manufacturing companies, situated in Ames, Iowa (USA), Neumünster (Germany),
and Norborg (Denmark). Sauer-Danfoss mainly manufactures and exports hydraulic
products and is one of the main leaders within the hydraulic motor sector. The
company has more than 18 production and license companies in North America,
Europe and East Asia. It is among the largest manufacturers and suppliers of
mobile hydraulics in the world today. Sauer-Danfoss produces mobile hydraulic
products for different applications such as agricultural, construction; road
building, material handling, municipal, forestry and turf care applications.
These products contribute to saving energy, increasing comfort and boosting
efficiency. Sauer-Danfoss is recognised for, and always aspires towards using
advanced technology and providing high quality in both products and
manufacturing processes, and for taking environmental issues into account.
The “Sauer-Danfoss” which is situated in Nordborg in the Southern part of Denmark (one of the main manufacturing companies) manufactures hydraulic motors, steering systems and hydraulic valves as main products. (Sauer-Danfoss was previously known as Danfoss
until July 2000.) The company manufactures more than 10,000 different products
with 1,600 different hydraulic motors. Types,
variants and size of the hydraulic motors vary with respect to applications.
The OMV/W-800 (conical shaft) model type hydraulic motor is chosen as a physical product. The motor is 37,636 kg in weight. The technical data of the reference product is illustrated in table (1.1). The model with 800 displacements is designed in five different shapes i.e. OMV- 800 tapered shaft, OMV/W-800 cylindrical shaft and OMV/W-800 conical shaft. The product designation OMV/W stands for OM means “Orbit Motor”, V is just a letter and W means “wheel“. 800 indicates the displacement of the hydraulic motor. The motors are different in shape and weight. The models weigh 37,379 kg, 36,965 kg, 37,636 kg, 37,625 kg and 38,135 kg. The motors are designed on an approx. 220/min speed range. EDIP
Computer Tool Introduction
1)
the Unit Process Database 2)
the Modelling Tool and 3)
the Calculation facilities. The
EDIP-tool works with the Unit Process Database. The In-build Unit Process
Database contains approx. 750 process cards, covering all types of systems.
Approx. 200 of these are in the category “substances” leaving over 500 unit
processes, which are categorized in: materials, transport systems, energy
system, disposal systems, production processes, ancillary materials, substances
etc. The
EDIP PC-tool contains the necessary functionality to fully support the work
process in life cycle based environmental assessment. The quantitative part of
the process data is scalable, making it possible for users to apply data in
other contexts. The
PC-Tool is able to calculate an inventory or assess the environmental impacts
for the whole system or any part of the system. Furthermore the PC-Tool is able
to calculate impact potentials and further normalized and weighted impact
potentials on the basis of given methodology in the EDIP book. (Found
mistakes and weak points in the PC model during project data simulations, are
reported in detail in appendix E).
MECEEO Model and Hydraulic book Introduction
The
MECEEO model covers Materials, Energy, Chemicals, Emissions,
Economy and Other data. The model is developed on the basis of
EDIP (Environmental Design of Industrial Products) MECO table methodology. The
model is developed on the web. Please note that the model supports Microsoft
Explorer. Please avoid using it on Netscape, it may not be able to display the
correct format.
The
model assists in the estimation of materials, energy, chemicals, economy,
emissions of the hydraulic products (motors). By entering the motor weight in
the input column, the user will be able to see the rough estimation of the
hydraulic products. Please note that the model is settled on default (OMV/W-800)
values, which will support the estimate of all OMV/W types motors. In order to
evaluate others types of (TMT, OMT, OMR) motors, the optional data must be
changed. The
model is developed on the basis of functional unit optional values, which is
user defined. The model supports the user to provide rough values in the product
system in order to find the problematic area (stage) in the product. The user
can see significant changes in the product system by replacing optional default
values. For example, the user can see the significant changes in the product
system by increasing 1% efficiency in the functional unit values. The
MECEEO model calculates the significant impact potentials on different stages of
the product system on the basis of given methodology in the EDIP book on
weightings criteria. Note:
In order to run the model, please see user guide in chapter 5, section (5.2).
Please check documentation with CD-Rom for upgraded information.
Hydraulic book
The
idea behind this book is that the data collected on all stages are further
converted into d-BASE database, and the developed model is connected to that
database. The model is very flexible, and the data can
be changed by user choice in order to view the importance in changed data in a
graphic format, but it cannot be saved in the original results. The
hydraulic book software is developed similarly to market software, which can be
installed in the computer. For details, see the installation guide
in chapter 5, section (5.3) below. Note: The hydraulic book is incomplete as yet. It will be
developed later. The original capability will be attached with CD Rom. Please
chick CD-Rom and read about its capability and user guide in detail. Methodology
The EDIP (Environment
Design of Industrial Products) is designed for product
development. The method is thus suited to environmental assessment task(s) such
as “environmental assessment of reference”, “environment diagnosis”,
“environmental assessment of concepts”, and “environmental
assessment of details”, which arise in new and revising product
considerations. The EDIP provides LCA methodology from cradle-to-grave in the
product’s lifespan. According to the EDIP method, four applications for LCA in
the product development are: ¨
Generate
information on a product’s lifespan ¨
To
identify improvement potentials ¨
To
compare alternative solutions on a detail level ¨
To
compare alternative solutions on a concept level The
EDIP method contains four main phases; goal definition, scope definition,
inventory and impact assessment. The method is thus in agreement with SETAC’s
general guidelines for the content of a Life Cycle Assessment (Consoli et.
al., 1993). A procedure is assigned for each individual phase and it is
supported by examples and site-specific data in the theory chapter and case
study chapter. The EDIP methodology (Hauschild and Wenzel, 1997a)
supports the user to find proper solutions for the task of the LCA.
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