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0.1.1.1.1
Production Of
Materials (Raw materials):
Materials and components (in the form of raw parts) are supplied from several parts of the world and enter into manufacturing of the hydraulic motor OMV/W-800. The geographical locations of the subcontractors are given in the map shown in figure (3.9). All transport of materials from refining to production of material is included in the inventory. Please
note that the newly entered (on material, substances and processes) ID numbers
in the model (database) are similar to the EDIP database ID numbers. The main
processes and stages are recorded under “sub system” in the model database.
In order to check new entry in the database system, please check “user ID”
under title “bhander”). 0.1.1.1.1.1 Production of Cast Iron and Steel
¨
Preparation of Raw Materials ¨
Iron Manufacture ¨
Steel manufacture ¨
Manufacture of the finished steel products The processing steps that are mentioned above are used most commonly in Western Europe in iron and steel making. A detailed investigation is made on these four processing steps and reported in the detailed appendix A, chapter 1 and briefly reported below: 0.1.1.1.1.1.1
Geographical
coverage: The participating companies in the lifespan of the hydraulic motor are located in the whole world. The different qualities of cast iron and steels are supplied from several parts of the world and enter into the manufacturing of the hydraulic motor OMV/W-800. The geographical locations (figure (3.9) of the subcontractors are many: Germany, France, Columbus USA, Birmingham, Great Britain and Denmark. Different materials, i.e. cast iron, steel, rubber and packaging material (plastic bags and corrugated cardboard) are imported from different locations (illustrated in percentage (%) in figure (3.9). It was not possible to collect information on third party subcontractors. The geographical locations of the subcontractors (refining material locations) on raw materials and ancillary substance used to manufacture cast iron and steel are neglected in this study, because of time limitations and non obtainable data e.g. iron ore, coke and geographical locations. 0.1.1.1.1.1.2
Methodology:
The
manufacturing route of cast iron and steel is illustrated in figure (3.10).
Basically, after melting in a basic oxygen furnace or electric arc furnace, the
liquid of cast iron and steel is tapped from the furnaces by means of bottom
tapping, a method that, among other things, ensures slag free tapping, resulting
in metallurgical advantages. After tapping: ¨
the
cast iron is moulded, the liquid material is contained in a sand moulding house.
The moulding processes cool down liquid cast iron giving it the required shape. ¨ the steel is ladled, the liquid steel is treated in the ladle furnace, where the final refining takes place. The ladle furnace maintains the temperature in the liquid condition and creates conditions for refining the material to extremely precise chemical compositions of the steel. When the liquid steel is ready for casting, it is casted either through the ingot casting process or continuous casting process. After the casting process, the standard steel is ready in the form of rods, plates, wires and tin. 0.1.1.1.1.1.3
Processes Route and
Technology coverage The
blast furnace and direct reduction are included in this study in order to
develop a worldwide database system on primary steel and cast iron basic
production processes as illustrated in figure (3.10). Further, a higher
quality of steel-manufacturing route is assumed to be
through the basic oxygen furnace route and the electric arc furnace route (the
BF and the EAF respectively) with respect to
Western Europe cast iron and steel making methodology. It should be noted that
the three main routes are used to manufacture cast iron and steel i.e.
basic oxygen furnace route, electric arc furnace route and open-hearth furnace
route. The technologies such as the open-hearth process (being less than 7%
of the world steel production in 1996, IISI)
and ingot cast steel products (being less than 23% of the world in 1996,
IISI) are not considered in this study (in detail see appendix A, chapter
1, section (A.1.3.2)). 0.1.1.1.1.1.4
Raw material preparation
0.1.1.1.1.1.5
Data
collection and assumption This section includes cast iron and steel materials production related assumptions. For processes and materials, which are manufactured outside Sauer-Danfoss, no specific information is gathered and the modeling is based on assumptions, literature and LCI experts’ discussion. The main reason for excluding the external companies in the data collection on material and processes is because of the complexity of such a vast data collection. It would have been time consuming and extended the boundaries of the project. In other words, the goal of this study is to map out the impact potentials from the entire life span of the hydraulic product therefore the detailed investigation on raw material on external companies is not important in this case study. ¨
Data on preparation of raw materials are collected on a global basis from
the literature and LCI experts. This assumption is found to be significant in
the raw material stage by performing a sensitivity analysis as reported in appendix
A, chapter 5 section (A.5.4), which is further included in environmental
diagnosis section. ¨
The electrical and gasoline energy generation data and transport data are
used from the EDIP database system. The data on energy consumption on
preparation of raw materials such as iron ore, coal, coking and all other basic
resources and materials production are assumed to be on a global basis and used
from the computer EDIP-database system.
Electricity
consumption on production of raw iron (sponge/pig) is provided by Dansteel A/S,
Demark (course 80410 Report, steel production, 2000) is used and
furthermore generation of electricity used in the production of sponge/pig iron
is assumed with respect to material locations. The
electricity consumption on manufacturing
of standard cast iron (lamellar and SG-cast iron) provided by
Dania A/S (externally involved company) is used to develop a database
system and furthermore Danish
levels of electricity generation data available in the EDIP database are used.
The
electricity consumption on different processes (BF and EAF route) is
assumed to be 12 MJ/kg (IISI, LCI report, 1996)
and furthermore the level of electricity generation data available in the EDIP
database is used with respect to steel manufacturing locations. Electricity and transport in the raw material is not
significant in comparison with other parameters, but a brief discussion is added
in the later section on electricity consumption e.g. the electricity discussed
in the energy consumption parameter for the whole product system, because of
slight impacts on the impact categories found in the sensitivity analysis as
reported in appendix A, chapter 5, section (5.4). ¨
Data on manufacturing of SG-cast iron and lamellar cast iron (standard
irons) are collected from Dania A/S and further compared with literature
values. Missing data are estimated from literature such as IISI (International
Iron and Steel Institute) IDEA (International Database For Eco-profile
Analysis) and literature provided by “Nina Casperson”. Data is missing
on outputs from the processes. The gray cast iron outputs data from the
EDIP-database system are assumed to be valid for SG-cast ion and lamellar cast
iron. This part of the raw
material is found to contribute significantly to toxicities and waste impact
potential categories in the sensitivity
analysis as reported in appendix A, chapter 5 section (5.4), which is
further added in the environmental diagnosis in a later section e.g. the
resources discussed in materials parameter.
¨
Data on the production of crude steel is collected from literature, by
making questionnaires with involved companies (phone calls and letters),
literature such as IISI (International Iron and Steel Institute) IDEA (International
Database For Eco-profile Analysis) and other same product companies such
as Dansteel A/S. Furthermore data on steel manufacturing processes are
recorded in the database system with respect to locations. Required inputs and
outputs of ancillary materials are assumed on a global basis and further used
from EDIP-database system. The steel assumptions are
found to be significant in impact potentials categories the sensitivity
analysis as reported in appendix A, chapter 5 section (5.4), which are
further added in the environmental diagnosis in a later section e.g. the
resources discussed in materials parameter. ¨
Attempts were made to collect data on high quality steel from externally
involved companies that are actively involved in this study (See letters in
appendix G), but with very limited
co-operation from the companies. In order to complete the target,
the modification is made in crude steel data given in the EDIP-database system
and further compared with literature (IISI and IDEA) based data. The
average values are estimated on basic data and further data is developed on
different steel qualities on the basis of literature. The database is developed
by making assumptions from the EDIP-database on required raw material, ancillary
substances and resources on input and output material and substances. This
assumption is a part of the materials parameter, which is
also included in the later environmental
diagnosis section. ¨
Final
chemical compositions (alloying elements) on each quality of steel is
made based on literature information provided in
CD-ROM “Key to Steel 1998” (Chemical
composition data is estimated on the basis of German level data).
This assumption
is also a part of the materials parameter, which will be discussed later. Please
remember that the data reported in appendix A, is collected on the basis of 1 kg
cast iron and steel production. 0.1.1.1.1.1.6
Standard
Cast-iron manufacturing:
As
shown in figure (3.10) above, the primary inputs for standard cast iron
are raw cast iron (molten/sponge cast iron), FF scrap, graphite, silicon
carbide and ferrosilicon manganese materials, where the primary inputs for
molten/sponge iron manufacturing are sinter or pellets. Data on FF scrap,
graphite, silicon carbide and ferrosilicon manganese materials are available in
the EDIP-Database system. Detailed data on inputs and outputs materials and
emissions on SG-cast iron and lamellar cast iron are reported in appendix
A, chapter 1, section (A.1.2.3) and section (A.1.2.4). Missing data on raw
cast iron (molten/sponge cast iron) production data is collected on the
basis of literature and briefly discussed below: Molten/Sponge
cast iron (Blast furnace process): It
should be noted that each ton of iron requires about 1,5 ton of sinter or
pellets charged into the furnace (IDEA-International Database For Ecoprofile
Analysis, Draft, May 1991). Iron ore as well as sinter or pellets contain
iron primarily in the form of iron oxide. The production method of raw
cast iron is: The blast furnace/direct reduction process is charged from the top with
sinter, coke, limestone and relatively small amounts of iron ore. The detailed
data is reported in appendix A, chapter 1, section (A.1.2.1&2). It is
important to know that: Burning
the coke creates (producing gases, mainly CO) sufficient heat to melt the iron
and slag (mainly oxide of calcium and ore impurities) forms on top of the
molten iron (at about 1700 °C).
It is also called pig iron. Pig iron includes a typical composition of 93,8%
Iron (Fe), 4,7 % Carbon, 0,7 % manganese (Mn), 0,6 silicon (Si), 0,1 %
phosphorus (P) and 0.04 % Sulfur (S) by weight (IDEA Draft, May 1991). In
the direct reduction plant, iron pellets are charged into the furnace as
illustrated in figure (A1.5), appendix A, where the oxygen content in the
iron, still in its solid state, is lowered through reduction with carbon. (In
Western Europe 97% in the form of natural gas.) After the direct reduction step,
so-called sponge iron is produced. Sponge iron contains at least 92% pure iron
(Fe) remainder Carbon, manganese (Mn), silicon (Si), phosphorus (P) and Sulfur
(S) (IDEA Draft, May 1991). 0.1.1.1.1.1.7 Steel Production
Crude steel is more formable and has a higher strength than iron because of lower carbon, phosphorus and sulfur levels. The steel-manufacturing route is illustrated in figure (3.10). The
hydraulic motor type OMV/W-800 is manufactured with ten different steel
qualities elaborated in table (3.3). The specifications of each steel
production such as type and amount of included alloying elements, coating
thickness, vary from site to site and are a function of technology, equipments
and product ranges at the sites involved. The investigation on the manufacturing
of steel is made on each specific steel production. Data is collected from
actively involved companies, estimated from a literature survey, through
discussions with LCI experts and assumptions. The chemical compositions (alloying elements) on different qualities of
steel are based on German levels. All
steel related assumptions are reported in the previous section and prepared data
recorded in the database system. The steel production is briefly discussed
below: Production
of Molten steel and steel slabs:
Molten
steel is manufactured through the basic oxygen furnace process or the electric
arc furnace process. In order to complete the global basis study, both processes
are included in the case study.
Figure
(3.11):
Molten steel Production by basic oxygen or electric arc furnaces and further
steel casting by ingot or continuous casting process. The basic oxygen furnace and electric arc furnace process
(EAF): In the basic oxygen furnace the molten pig iron (primary iron) and scrap
are charged into the furnace and lime, ferromanganese, and fluxes are added to
the furnace in order to reduce the carbon content of the iron and promote fusing
and prevent the formation of oxide. In the electric
arc furnace, the charge is either 100% steel scrap in the scrap melting route or
a mixture of sponge/pig iron and steel scrap. CaO, ferromanganese and fluxes,
such as CaF2, are added to the furnace. High power graphite
electrodes that descend through the furnace roof melt the charge. The oxygen is
used to reduce the carbon level of the hot iron to make crude steel.
The
method of these processes is to heat up at a high temperature and the carbon in
the hot metal is then reduced by oxygen lanced into the furnace to make crude steel.
During the oxygen and metal reaction under high temperature, large quantities of
iron oxide, carbon monoxide (CO) and CO2 is formed, which is the main
cause of persistent toxicity, human and eco-toxicity in the raw materials stage.
Iron oxides produce CaO slag with calcium, which can be used to re-new
(recycled) products (In this study 100% slag is assumed to be deposited into
landfills). The crude steel generally has a carbon content of less than 2,0%
(IDEA, draft, may 1991). The
conventional route of BF and EAF steel making is
illustrated in the flow chart as shown in figure (3.10) and the graphic
view of BF and EAF routes are drawn schematically in figure (3.11) and in
detail reported in appendix A, chapter 1, section (A.1.3.2). Steel casting process: Molten steel is casted using either the continuous or ingot casting process. In Western Europe, the casting process is done 70,5% by continuous process and 29,5% the ingot way (IISI, 1986). The methods of ingot and continuous process are illustrated in figure (3.11) and the continuous process is considered in this study and data is collected from Dansteel A/S and reported in appendix A, chapter 1, section (A1.3.3.3). (Heated ingots are also rolled in primary mills to slabs of about the same shape as continuously cast ones.) 0.1.1.1.1.1.8 Manufacturing of high qualities of steel The
high qualities of steel are imported from various parts of the world as shown in
figure (3.9). The data are prepared on different qualities of steel are
reported in detail in appendix A, section (1.3.4). 0.1.1.1.1.2 Acrylonitrile-Butadiene-Rubber (NBR)The parts manufactured with rubber are not important in weight in the hydraulic product. An investigation is not made on rubber production because of time limitations. The assumptions are reported below: 0.1.1.1.1.2.1
Geographical
coverage: The
manufacturing companies are located in Sweden and Germany. 13% of rubber is
imported from Sweden and 15 % of the rubber parts are imported from Germany. The
rest of the rubber parts are imported from the different parts of the Denmark. Please note that the raw materials extraction and production
of crude rubber is not investigated with respect to material importance in the
product. The material Acrylonitrile-Butadiene-Rubber (NBR) is a polymer of butadiene used to manufacture rubber parts (Vaellingby, Sweden, phone calls information). Data on the production of NBR rubber is used from the EDIP database system. It is not important in the emissions profile found in the sensitivity analysis in appendix A chapter 5, section (5.4), and is not further discussed. The
raw material consists of oils, which are refined to make NBR rubber, among other
compounds like natural gas, uranium, manganese, sodium chloride, coal etc.
0.5414 kg material is used to manufacture of NBR rubber parts (EDIP database
calculation). Electricity data on rubber
production is assumed to be similar to plastic (PUR) production, which is
provided by “Life Cycle Check” Translation, 2 drafts (Henrik et al)
on the production of plastic (PUR) (see appendix F, table (F1.3).
Detailed data on NBR rubber is reported in appendix A, chapter 2. The
raw material and electricity assumptions are not found to be significant and
therefore only briefly discussed in the environmental diagnosis in raw materials
and energy consumption parameters. 0.1.1.1.1.3 PlasticAs
reported in detail in appendix A, chapter 3, the polyethylene (PET)
plastic is assumed to be used for manufacturing hydraulic product parts (seal
plug) and packaging bags. Data on the production of PET is used from the EDIP
database system. The raw material consists of oils, which are refined to make
PET rubber, among other compounds like natural gas, uranium, manganese, sodium
chloride, Fe, coal etc. 1.339 kg material is used to manufacture plastic parts (EDIP
database calculation). An energy profile given in appendix
F table (F1.3), provided by “Life Cycle Check” Translation, 2
drafts (Henrik et al) is used. As mentioned in the previous section, the
PET is assumed to be manufactured with 100 % primary material. The primary
energy the production of plastic requires is 80 MJ/kg. It is not
important in the emissions profile found in the sensitivity analysis in appendix
A chapter 5, section (5.4), and is not further discussed separately, but
only briefly discussed in the environmental diagnosis in raw materials
parameter. 0.1.1.1.1.4 Corrugated board (packaging box)Corrugated
board is used to make packaging boxes for motors. Primary fluting and liner for
corrugated cardboard is assumed to be used to make the final packaging box. Data
on the production of cardboard is estimated on the basis of available data in
the EDIP-database system and literature based data and in detail reported in appendux
A chapter 4. Corrugated
board consisting of 70% liner and 30% fluting has been assumed in the
manufacturing of packaging boxes. It has also been assumed that reclaimed
corrugated board is used for liner and fluting, in the same proportions as the
outward product. The data has been collected for 1 kg corrugated board with a
dry matter content of 93%(Packaging
and the Environment, Anne et. al, 1991) and reported in appendix A, section (A.4.2). The
fluting is produced with a yield of 83%. Ancillary substances consist of 3,4
grams sodium hydroxide per kg
fluting and 8,5 grams sodium
sulphite per kg flutting. For the gluing of layers of liner and fluting to form corrugated board and manufacturing of the finished packaging, 17,2 grams maize starch, 0.3 g NaOH and 0,2 grams borax is used (Packaging and the Environment, Anne, et. al, 1991). This assumption is further found to be insignificant in the hydraulic product system, therefore it is not included in the discussion. The energy consumption on the production of one kg of corrugated board is calculated on the basis of given data in literature “Packaging and the environment” written by Tillman, Baumann, Eriksson and Rydberg, Chalmers Industriateknik, Sweden, 1991 and reported in appendix A, section (A.4.3). The energy consumption in the raw material stage does not contribute to potential impacts significantly; therefore it is not investigated in detail, including corrugated cardboard electrical energy consumption. | |||||||||||||||||||||||
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