Cables - Estimate of Energy Consumption and CO2 Emission Associated With The Production, Use and Final Disposal
Cables - Estimate of Energy Consumption and CO2 Emission Associated With The Production, Use and Final Disposal
Report: PVC-Cab-200511-2
Index
1. Summary................................................................................................ 1
2. Background ........................................................................................... 3
2.1. Objective and calculation bases .................................................................................... 3
2.2. Contents of the document.............................................................................................. 4
3. The life cycle of a cable......................................................................... 5
4. Estimate of energy consumption and CO2 emission attributable to 1
m of cable for electricity distribution. ....................................................... 6
4.1. Calculation base ............................................................................................................ 6
4.1.1. Dimensions............................................................................................................ 6
4.1.2. Materials................................................................................................................ 6
4.1.3. Scenarios analysed ................................................................................................ 7
4.2. Extraction and production of materials ......................................................................... 9
4.3. Production of the cable................................................................................................ 11
4.4. Installation and dismantling of the cable..................................................................... 11
4.5. Use of the cable. .......................................................................................................... 12
4.6. Recycling..................................................................................................................... 13
4.7. Final disposal .............................................................................................................. 13
4.8. Transport ..................................................................................................................... 13
4.9. Emission factors .......................................................................................................... 14
5. Results and comparative analysis...................................................... 15
6. Conclusions ............................................................................................ 1
7. References .............................................................................................. 3
i
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Index of tables.
Table 4.1. Characteristics of the cables selected.......................................................8
Table 4.2. Characteristics of the cables considered: maximum resistance at
20ºC and maximum admissible intensity...............................................................8
Table 4.3. Mean composition of the insulants of the standard cables
considered..................................................................................................................8
Table 4.4 Energy consumption figures for extraction of natural resources and
production of materials..........................................................................................10
Table 4.5. Estimated energy consumption in the usage stage of the cable.
Considering heat losses through Joule effect. ...................................................12
Table 4.6. CO2 emission factors. ...................................................................................14
Table 5.1. Energy consumption and CO2 emission estimates for the different life
cycle stages of 1 m of RS 35 mm2 single-pole cable with copper conductor
and PVC insulant. ....................................................................................................16
Table 5.2. Energy consumption and CO2 emission estimates for the different life
cycle stages of of 1 m of RS 35 mm2 single-pole cable with copper
conductor and PVC insulant, with 25% recycled PVC in the insulant. ..........16
Table 5.3. Energy consumption and CO2 emission estimates for the different life
cycle stages of of 1 m of RS 25 mm2 single-pole cable with copper
conductor and XLPE insulant, with PVC coating...............................................17
Table 5.4. Energy consumption and CO2 emission estimates for the different life
cycle stages of of 1 m of RS 25 mm2 single-pole cable with copper
conductor and PE insulant, with mineral charge. .............................................17
Table 5.5. Energy consumption and CO2 emission estimates for the different life
cycle stages of of 1 m of RS 25 mm2 single-pole cable with copper
conductor and PE insulant, with mineral charge, with 25% recycled PE. .....18
Table 5.6. Summary of energy consumption and CO2 emissions associated with
each of the life cycle stages of cables with insulants made of different
materials......................................................................................................................1
Table 5.7. Energy consumption and CO2 emissions associated with the life cycle
of single-pole cables with copper conductor and insulation made of
different materials. Summary...................................................................................2
ii
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Index of figures.
Figure 3.1. Flowchart of the life cycle of a cable........................................................5
Figure 4.1. Commercial single-pole cables with insulant made of different
materials......................................................................................................................6
Figure 5.1. Estimate of energy consumption and CO2 emissions associated with
the life cycle of single-pole cables for electricity distribution with PVC
insulant. .....................................................................................................................18
Figure 5.2. Estimate of energy consumption and CO2 emissions associated with
the life cycle of single-pole cables for electricity distribution with PVC
insulant, with 25% recycled material in the composition. ................................19
Figure 5.3 Estimate of energy consumption and CO2 emissions associated with
the life cycle of single-pole cables for electricity distribution with XLPE
insulant ......................................................................................................................19
Figure 5.4. Estimate of energy consumption and CO2 emissions associated with
the life cycle of single-pole cables for electricity distribution with PE insulant
with mineral charge ................................................................................................20
Figure 5.5 Estimate of energy consumption and CO2 emissions associated with
the life cycle of single-pole cables for electricity distribution with PE insulant
with mineral charge, with 25% recycled material in the composition...........20
iii
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
1. Summary
The standard case for the study to be carried out was a single-pole cable with
copper conductor and PVC insulation, with a rated section of 35 mm2. The
elements for comparison purposes selected were cables with insulant made of
XLPE cross-linked polyethylene and PE with mineral charge, with a rated section
of 25 mm2, in such as way that the three types of cables compared allow a
maximum admissible intensity as close as possible, taking Low-voltage
Electrotechnical Regulations into consideration.
The XLPE cable additionally has a PVC coating since, although the choice of
insulants with mixed materials has been avoided throughout, it has been noted
that, for the specific case of cross-linked polyethylene, it is not usual to find
single-pole cables without a coating of a different composition.
In the case of the PVC and the PE with mineral charge, the option of
introducing 25% recycled materials into the cable composition was
contemplated, although at present, the use of recycled raw materials is not
common. Cross-linked polyethylene is not usually subjected to recycling
processes because of its structure, and this option has therefore not been
considered.
The cable presenting the best results from the viewpoint of the environmental
indicators considered is PVC with 25% recycled materials in its composition, with
an energy consumption throughout the life cycle of 144 kWh m-1 and the
associated CO2 emission of 65 kg.
Not including recycled material in the cable signifies a 0.1% increase in energy
consumption and in CO2 emissions. The new PVC cable considered, throughout
the life cycle, consumes 145 kWh m-1, and signifies emission of 65 kg of CO2.
1
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
There follow the polyethylene cables with mineral charge (with and without
recycled material), which signify consumption of 198 kWh m-1 and emission of
88 kg of CO2.
The PE cables with mineral charge, either with or without recycled materials,
and the cross-linked polyethylene, signify very similar energy consumption
figures, with a difference of less than 1%.
Including 25% recycled materials in the composition of the PVC cable signifies
an energy saving in the region of just 0.1%.
2
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
2. Background
Furthermore, cables can be divided into two major groups: single-pole and
multi-pole. The first consist of one single conductor wire, normally insulated by
one or more dielectric materials, whilst the second comprise bundles of a
certain number of conductors independently insulated and coated with a
common dielectric.
All these factors and different possible layouts affect the characteristics of the
insulant the conductor must be protected with.
For the study, the simplest kind of cables available on the market have been
selected: single-pole cables used in domestic electrical installations with no
outer coating; i.e. those solely comprising the conductor and the insulant
produced from one single material.
This focus is based on the consideration of all the stages of a study of the Life
Cycle Assessment (LCA), although the scope focuses solely on the two aspects
indicated above. An LCA cannot be used to compare products with each
other, but rather services and/or product quantities carrying out the same
function.
3
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Cables are classified according to the rated section of the conductor, which
indicates the maximum resistance of the cable at 20ºC (UNE-EN 60228). The
maximum admissible intensity the cable may conduct will depend on the rated
section, on its insulation type and on the type of installation. For multi-pole
cables, the layout and number of single-pole cables it comprises will also have
an influence (Low-voltage Electrotechnical Regulations; Royal Decree 842/2002
of the 2nd August 2002).
A description is given of the stages comprising the life cycle of the cable, as
well as the calculation hypotheses and scenarios for the comparative analysis.
The magnitudes of the significant electrical consumption values are indicated,
as well as the energy sources defining the CO2 emission factors.
The results obtained are set out in detail and summary form. The estimates
obtained are analysed, identifying the alternatives with the lowest energy
consumption and CO2 emission values, in ascending order.
4
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Figure 3.1 shows the typical life cycle of a cable, focusing on energy use and
the corresponding atmospheric emissions.
The first stage corresponds to extraction of the raw materials and supply of
materials for production of the cable.
The second stage consists of actual production of the cable, which will depend
on both the type of cable and on the materials used in its composition.
Next, the stages of installation and use of the cable are considered. It is
estimated that all the cables have a mean lifetime of 50 years.
Once the cable’s usage period has ended, it is dismantled and transported to
a recycling centre. The non-recyclable portion is sent to a final waste-disposal
management centre.
EXTRACCIÓN
EXTRACTION OF PRODUCTION INSTALACIÓN
INSTALLATION USO USE
DE RECURSOS PRODUCCIÓN
RESOURCES AND OF CABLE
CABLE OF CABLE
CABLE vidaMean life
media
PRODUCCIÓN
PRODUCTION OF 50 50 years
años
MATERIALES
MATERIALS 0,03 kWh
0,03 kWh 0,03 kWh
0,0 kg CO2
0,4 kWh DISPOSICIÓN
FINAL
FINAL
DISPOSAL
Emisiones CO2
CO2 emissions
3%
0,01 kWh
Consumo energético
Energy consumption 0,01 kWh
5
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
4.1.1. Dimensions
4.1.2. Materials
PVC
XLPE (cross-linked polyethylene)
PE with mineral charge
These materials were chosen because they are the most widely used as
insulants.
Specifically, the calculation base used was a copper cable 1 m in length, with
PVC insulation with a rated section of 35 mm2, which signifies that it can admit a
maximum intensity of 86 A (for the type of installation considered: embedded
under tube).
6
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Cables comprising solely the conductor and the insulating layer are
considered, in order to simplify the comparative study, to avoid mixtures of
materials, which are common in more complex cables. However, in practice,
cables made of XLPE insulant are not usually available without coating, not
even for use in domestic electrical installations. In order to achieve as
representative a result as possible of actual circumstances, it was decided to
include a PVC coating in the XLPE cable.
5) Cable with PE insulant with mineral charge, with 25% recycled material.
To size these cables, the reference taken was commercially available single-
pole cables with a rated section of 35 mm2 in the case of PVC, and a rated
section of 25 mm2 in the case of XLPE and PE with mineral charge.
Table 4.2 shows the electrical characteristics of the cable (maximum resistance
at 20 ºC and maximum admissible intensity) taken for reference purpose to
make the comparison and to select the different standard cables for each
material.
The weight calculated per metre of cable differs slightly from the commercial
weight specified by the sources consulted; to calculate this, the volumes
determined from the commercial dimensions were used, along with a standard
composition for each insulant, which is indicated in Table 4.3. It was considered
advisable to establish the specific weight of each cable this way, and not the
weight supplied in the commercial specifications, to give the study greater
generality and to prevent it being limited to the cable produced by any one
specific manufacturer.
7
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Insulant
Outer Coating Tabulated
RS Outer thicknes
Insulant ∅ thickness weight Calculated weight (kg m-1)
(mm2) coating s
(mm) (mm) (kg m-1)
(mm)
Copper
insulant coating TOTAL
conductor
PVC 35 no 13.5 2.6 0.45 0.31 0.15 -- 0.46
XLPE 25 PVC 11.2 0.9 1.4 0.32 0.22 0.03 0.06 0.31
PE with
mineral 25 no 9.0 1.2 0.27 0.22 0.06 -- 0.28
charge
Sources selected for sizing of the cables:
PVC cable. Sintenax valio.
XLPE cable. Retenax valio.
PE cable with mineral charge. Afumex 750.
Prysmian.
(http://www.ar.prysmian.com/es_AR/cables_systems/energy/catalog_prices/catalog/catal_cat_
ar.jhtml, November 2005)
Table 4.3. Mean composition of the insulants of the standard cables considered
LDPE 40 915
PE with mineral Aluminium
25 63.6 36 2420 1450 0.06
charge hydroxide
Magnesium
24 2360
hydroxide
(1). The mean composition of the different insulants was provided by Benvic.
(2). Excluding the PVC coating.
(3). Due to the difficulty of establishing the density of the silane compound used as the cross-
linking agent, the density of the commercial XLPE was considered; the following compound was
used as the standard case: LUTENE SP3450NT LG CHEM.
8
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
(http://www.chemwide.co.kr/product3/0matter/matter_type.jsp?prodSeq=26&locale=en&prodSelect=
98,93,99,91, November, 2005)
The use of recycled plastics for cable production is not a common situation at
present.
In the case of XLPE, recycling is not possible. With regard to PVC and PE with
mineral charge, they are usually separated out and recycled for other uses.
However, cases including 25% recycled material in the cable composition have
been included, as considerable efforts are being made in this direction, and it is
believed that use of them in the future could become commonplace.
For the PVC, the energy consumption and CO2 emission presented in the
document “Estimate of the energy consumption and CO2 emission associated
with unit production of PVC” (Baldasano and Parra, 2005) have been used. The
values of the calculation criterion that considers the joint obtention of PVC and
caustic soda are used. The energy consumption for the manufacture of PVC is
7.2 kWh kg-1; and the associated CO2 emission factor is 0.3 kg CO2 kWh-1.
In the case of the mineral charge for the PVC, calcium carbonate, energy
consumption of 0.03 kWh kg-1 is estimated based on the data available in the
“Reference Document on BAT in the cement and lime manufacturing
industries” (IPPC, 2001). It is considered that the energy used is based on diesel,
and the emission is established at 0.3 kg CO2 kWh-1.
9
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
For the plasticizer DIDP, the energy consumption and CO2 emissions associated
with a standard phthalate ester were chosen, with the result of 7.1 kwh kg-1 and
0.3 kg CO2 kWh-1 (ECPI, 2001).
The energy consumption and CO2 emissions associated with the extraction and
supply of the remaining materials: lubricants, flame-retardants, etc., were similar
to the base of the insulant in each case (PVC, LDPE). It is considered that the
margin of error introduced by this approximation is not excessively large, given
that the contribution of these components in terms of weight is between 3%
and 5% of the total for the cable.
The energy consumption figures for the materials are summarized in Table 4.4.
Table 4.4 Energy consumption figures for extraction of natural resources and production
of materials.
Energy consumption
Material
(kWh kg-1) Source
PVC 7.19
(Baldasano and Parra, 2005)
Mg Chemlink Consultants
2.63
Hydroxide (http://www.chemlink.com.au/mag&oxide.htm,
September 2005)
Ca
0.06 Reference document on BAT in the cement and lime
Carbonate manufacturing industries (IPPC, 2001)
10
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
The mean energy consumption of the production process was estimated in line
with the data obtained for a particular production company (Ascable (2002)),
giving the result of consumption of 0.36 kWh per kg of cable produced.
To estimate the CO2 emissions associated with this process, it was considered
that the energy sources used were electricity and diesel.
Embedded installations:
Surface installations:
The type of installation affects the maximum admissible intensity the cable may
conduct; in this case, the installation was taken as embedded under tube.
11
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
The energy consumption associated with the usage stage of the cable was
estimated taking energy losses consequent to heat dissipation through Joule
effect in the conductor into account. The resistance values for conductors
tabulated in UNE EN 60228 standard were used, and the maximum admissible
intensities were those indicated in the Low-voltage Electrotechnical Regulations
(REBT) (Royal Decree 842/2002 of the 2nd August 2002).
To calculate the energy losses, the mean lifetime of the cable was taken into
consideration, taken as 50 years for all the materials, assuming a usage time of
8 hours per day.
The circulating intensity considered was the same for the three types of cable,
taking half the maximum admissible intensities for reference, in this case 86 A,
corresponding to the cable with PVC insulation with rated section of 35 mm2.
This therefore signifies a circulating intensity of 43 A.
The heat losses through Joule effect are quantified according to equation Eq 1.
Q = I 2 ·R·t [Eq 1]
where Q is the energy dissipated (J), I is the circulating intensity (A), R the
resistance of the conductor (Ohm) and t the time considered (s).
The results obtained for energy consumption and CO2 emissions corresponding
to the usage stage of the cable are shown in Table 4.5. The relative importance
of this stage is 96-99%, for both energy consumption and CO2 emissions.
Table 4.5. Estimated energy consumption in the usage stage of the cable. Considering
heat losses through Joule effect.
12
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
4.6. Recycling
It is assumed that 97% of the materials contained in the cable insulation are
recyclable, except in the case of the cross-linked polyethylene, which is
assumed to be sent entirely for final disposal. The remaining 3% consists of waste
materials which are deposited in a disposal site
Since the cables being considered are single-pole cables with just one material
as the insulant, they can be recycled by a mechanical process. In more
complex cables, which comprise different materials in the insulation, processes
with selective solvents normally have to be used, such as the Vinyloop process
for PVC.
It is assumed that the recycling process for copper signifies an energy saving of
75% with regard to the original production process (Secretary of State’s Office
for Energy, industrial development and small and medium-sized enterprises,
Ministry for the Economy, 2001), whereby this would signify consumption of 1.2
kWh kg-1. Considering that the energy sources are coal and electricity,
50%/50%, the emissions associated with the recycling process are 0.4 kg CO2 kg-
1.
4.8. Transport
It is assumed that the transport connecting the different stages of the life cycle
is performed with cargo trucks which run on diesel, and which have an energy
demand of 0.00073 kWh km-1 kg-1 (WEC, 1998). This value is applicable to
Western Europe.
A mean distance of 100 km was considered for transport in all cases: transport
of materials to the production plant, transport of the cable to the installation
site, transport for recycling and for final disposal.
13
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Table 4.6 shows the base CO2 emission factors used in each stage, according
to the composition or type of energy supply already indicated for each case.
Emission factor
t C TJ-1
Energy source / fuel (IPCC, 1996) t CO2 TJ-1 t CO2 MWh-1
Spanish electrical mix 0.443*
PVC production at Hispavic - Vinilis (Martorell) 0.284*
XLPE production 1.7 0.233
PE production 1.7 0.270
DIDP production 1.8 0.257
Aluminium hydroxide production 0.225
Diesel / fuel-oil 20.2 74.1 0.267
Natural gas 15.3 56.1 0.202
Coal 26.2 96.1 0.346
* Deduced in the document: “Estimate of the energy consumption and CO2 emission associated
with unit production of PVC”, JM Baldasano and R. Parra. January 2005".
¶ Corresponds to the calculation criterion that considers the objective of joint obtention of PVC
and caustic soda.
14
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
The energy consumption and CO2 emission figures for each of the cases
studied are set out in tables 5.1 to 5.5, and in diagram form in figures 5.1 to 5.5.
Tables 5.6 and 5.7 show a summary of the results obtained for each of the
materials.
The stage of the life cycle which signifies the largest energy consumption and
the highest CO2 emissions into the atmosphere is use of the cable. A mean
lifetime of 50 years has been considered for all the cables, with use of 8 hours
per day, and the losses through Joule effect have been estimated, resulting in
a contribution of between 97% and 99% to the energy consumption and to the
CO2 emissions for all the cases.
For the cases of cables with PE insulation with mineral charge and XLPE, the
importance of this stage is even less, not exceeding 1% of the total.
The cable presenting the best results from the viewpoint of the environmental
indicators considered is PVC with 25% recycled materials in its composition, with
energy consumption throughout the life cycle of 144 kWh m-1, and the
associated CO2 emission of 65 kg.
The new PVC cable considered consumes 145 kWh m-1 throughout the life
cycle, and signifies emissions of 65 kg of CO2.
The polyethylene cables with mineral charge (with and without recycled
material) and the cross-linked polyethylene cable signify consumption of 198
kWh m-1 and 199 kWh m-1 respectively, and emission of 88 kg of CO2.
15
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Table 5.1. Energy consumption and CO2 emission estimates for the different life cycle
stages of 1 m of RS 35 mm2 single-pole cable with copper conductor and PVC insulant.
Energy
CO2 emissions (kg
consumption % %
CO2 m-1)
(kWh m-1)
Extraction and supply of materials 2.29 1.59 1.70 2.63
Transport of materials to the
0.03 0.02 0.01 0.01
production plant
Production of the cable 0.17 0.11 0.07 0.11
Transport of the cable for
0.03 0.02 0.01 0.01
installation
Installation 0.00 0.00 0.00 0.00
Use 141.57 97.95 62.69 96.97
Dismantling 0.00 0.00 0.00 0.00
Transport to recycling 0.03 0.02 0.01 0.01
Recycling 0.37 0.26 0.15 0.23
Transport to final disposal 0.01 0.00 0.00 0.00
Final disposal 0.01 0.01 0.00 0.01
TOTAL 144.53 100.00 64.65 100.00
Table 5.2. Energy consumption and CO2 emission estimates for the different life cycle
stages of 1 m of RS 35 mm2 single-pole cable with copper conductor and PVC insulant,
with 25% recycled PVC in the insulant.
Energy
CO2 emissions (kg
consumption % %
CO2 m-1)
(kWh m-1)
Extraction and supply of materials 2.17 1.50 1.67 2.58
Transport of materials to the
0.03 0.02 0.01 0.01
production plant
Production of the cable 0.17 0.11 0.07 0.11
Transport of the cable for
0.03 0.02 0.01 0.01
installation
Installation 0.00 0.00 0.00 0.00
Use 141.57 98.04 62.69 97.03
Dismantling 0.00 0.00 0.00 0.00
Transport to recycling 0.03 0.02 0.01 0.01
Recycling 0.37 0.26 0.15 0.23
Transport to final disposal 0.01 0.00 0.00 0.00
Final disposal 0.01 0.01 0.00 0.01
TOTAL 144.40 100.00 64.61 100.00
16
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Table 5.3. Energy consumption and CO2 emission estimates for the different life cycle
stages of 1 m of RS 25 mm2 single-pole cable with copper conductor and XLPE insulant,
with PVC coating.
Energy
CO2 emissions (kg
consumption % %
CO2 m-1)
(kWh m-1)
Extraction and supply of materials 1.70 0.86 0.50 0.57
Transport of materials to the
0.02 0.01 0.01 0.01
production plant
Production of the cable 0.11 0.06 0.05 0.06
Transport of the cable for
0.02 0.01 0.01 0.01
installation
Installation 0.00 0.00 0.00 0.00
Use 196.41 98.91 86.98 99.23
Dismantling 0.00 0.00 0.00 0.00
Transport to recycling 0.02 0.01 0.01 0.01
Recycling 0.25 0.13 0.10 0.11
Transport to final disposal 0.01 0.00 0.00 0.00
Final disposal 0.01 0.01 0.00 0.00
TOTAL 198.57 100.00 87.66 100.00
Table 5.4. Energy consumption and CO2 emission estimates for the different life cycle
stages of 1 m of RS 25 mm2 single-pole cable with copper conductor and PE insulant,
with mineral charge.
Energy
CO2 emissions (kg
consumption % %
CO2 m-1)
(kWh m-1)
Extraction and supply of materials 1.33 0.67 0.39 0.45
Transport of materials to the
0.02 0.01 0.01 0.01
production plant
Production of the cable 0.10 0.05 0.04 0.05
Transport of the cable for
0.02 0.01 0.01 0.01
installation
Installation 0.00 0.00 0.00 0.00
Use 196.41 99.11 86.98 99.36
Dismantling 0.00 0.00 0.00 0.00
Transport to recycling 0.02 0.01 0.01 0.01
Recycling 0.26 0.13 0.10 0.12
Transport to final disposal 0.00 0.00 0.00 0.00
Final disposal 0.01 0.00 0.00 0.00
TOTAL 198.17 100.00 87.54 100.00
17
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Table 5.5. Energy consumption and CO2 emission estimates for the different life cycle
stages of 1 m of RS 25 mm2 single-pole cable with copper conductor and PE insulant
with mineral charge, with 25% recycled PE.
Energy
CO2 emissions (kg
consumption % %
CO2 m-1)
(kWh m-1)
Extraction and supply of materials 1.29 0.65 0.38 0.44
Transport of materials to the
0.02 0.01 0.01 0.01
production plant
Production of the cable 0.10 0.05 0.04 0.05
Transport of the cable for
0.02 0.01 0.01 0.01
installation
Installation 0.00 0.00 0.00 0.00
Use 196.41 99.13 86.98 99.37
Dismantling 0.00 0.00 0.00 0.00
Transport to recycling 0.02 0.01 0.01 0.01
Recycling 0.26 0.13 0.10 0.12
Transport to final disposal 0.00 0.00 0.00 0.00
Final disposal 0.01 0.00 0.00 0.00
TOTAL 198.13 100.00 87.53 100.00
97% 0,0 k
RECICLAJE
Otros usos
0,0 kg CO2
0,4 kWh DISPOS
FINA
Emisiones CO2
3%
0,01 kWh
Consumo energético
0,01 k
Figure 5.1. Estimate of energy consumption and CO2 emissions associated with the life
cycle of single-pole cables for electricity distribution with PVC insulant.
18
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
97% 0,0 k
RECICLAJE
Otros usos
0,0 kg CO2
0,4 kWh DISPOS
FINA
Emisiones CO2
3%
0,01 kWh
Consumo energético
0,01 k
Figure 5.2. Estimate of energy consumption and CO2 emissions associated with the life
cycle of single-pole cables for electricity distribution with PVC insulant, with 25%
recycled material in the composition.
0,0 kg CO2
0,3 kWh DISPOSICIÓN
FINAL
Emisiones CO2
3%
0,01 kWh
Consumo energético
0,01 kWh
Figure 5.3 Estimate of energy consumption and CO2 emissions associated with the life cycle of single-
pole cables for electricity distribution with XLPE insulant
19
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
0,0 kg CO2
0,3 kWh DISPOSICIÓN
Emisiones CO2 FINAL
3%
0,0 kWh
Consumo energético
0,01 kWh
Figure 5.4. Estimate of energy consumption and CO2 emissions associated with the life cycle of
single-pole cables for electricity distribution with PE insulant with mineral charge
97% 0,0
RECICLAJE
Otros usos
0,0 kg CO2
0,3 kWh DISPO
Emisiones CO2 FIN
3%
0,0 kWh
Consumo energético
0,01
Figure 5.5 Estimate of energy consumption and CO2 emissions associated with the life
cycle of single-pole cables for electricity distribution with PE insulant with mineral
charge, with 25% recycled material in the composition.
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Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Table 5.6. Summary of energy consumption and CO2 emissions associated with each of the life cycle stages of cables with insulants made of
different materials.
1
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Table 5.7. Energy consumption and CO2 emissions associated with the life cycle of single-pole cables with copper conductor and insulation
made of different materials. Summary.
% variation % variation
Conductor Energy
Conductor Outer Insulant PVC Maximum CO2 energy CO2
RS Weight resistance consumpti
1 m of single-pole cable diameter diameter thicknes coating admissible emissions consumed emission
(mm ) (kg m )
2 -1 at 20ºC on
(mm) (mm) s (mm) (mm) intensity (A) (kg CO2 m-1) compared compared
(ohm km-1) (kWh m-1)
with PVC with PVC
PVC with 25% recycled material 35 0.5 8.3 13.5 2.6 no 86 0.524 144.4 64.6 -0.1 -0.1
PVC 35 0.5 8.3 13.5 2.6 no 86 0.524 144.5 64.6 0.0 0.0
PE with mineral charge with 25%
25 0.3 6.6 9.0 1.2 no 96 0.727 198.1 87.5 37.1 35.4
recycled material
PE with mineral charge 25 0.3 6.6 9.0 1.2 no 96 0.727 198.2 87.5 37.1 35.4
XLPE 25 0.3 6.6 11.2 0.9 2.8 96 0.727 198.6 87.7 37.4 35.6
2
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
6. Conclusions
Single-pole cables with copper conductor and insulant comprising just one
material, normally used in domestic electrical installations, have been studied.
The standard case taken for the study was a cable with PVC insulant and rated
section of 35 mm2. The maximum admissible intensity this type of cable can
withstand is 86 A.
The elements for comparison selected were cables with cross-linked XLPE and
PE with mineral charge, as these are the materials most commonly used.
Cables with dimensions allowing a maximum admissible voltage as close as
possible to that for the PVC cable were considered, pursuant to the provisions
of the Low-voltage Electrotechnical Regulations; in both cases, these are
cables with a rated section of 25 mm2, admitting a maximum intensity of 96 A,
11% higher than the standard case.
The energy consumption and CO2 emission figures associated with each of the
stages of the life cycle of these three types of cable were estimated, taking 1 m
of cable as the unit of assessment.
In the case of the PVC and the PE with mineral charge, the option of including
25% recycled materials in the cable composition was contemplated, although
at present the use of recycled raw materials is not habitual. Cross-linked
polyethylene is not usually submitted to recycling processes because of its
structure, and this option has therefore not been considered.
The determinant stage for the energy consumption and CO2 emissions during
the life cycle of the cable is the usage stage. The energy losses through Joule
effect were estimated over a mean lifetime of 50 years, with 8 hours use per
day, signifying between 97 and 99% of the total consumption and emissions.
The cable presenting the best results from the viewpoint of the environmental
indicators considered is PVC with 25% recycled material in its composition.
Including 25% recycled PVC and copper in the cable composition signifies a
negligible energy saving: 0.1% compared with use of totally new materials. The
CO2 emissions are reduced by the same proportion.
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Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
Next come the cable insulated with PE with mineral charge, including 25%
recycled materials in its composition, and the PE cable with mineral charge
without recycled materials (with 37% more energy demand and 35% more CO2
emissions into the atmosphere than the new PVC cable).
Last come the XLPE cables, with 37% higher energy consumption than the PVC
cable taken as the standard case.
The results obtained for the PE cable with mineral charge and the XLPE cable
are practically identical (differences in the region of 1% energy consumption
per metre of cable).
It should be born in mind that using 25% recycled materials in production of the
cable barely varies the results for either the PVC or the polyethylene with
mineral charge.
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Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
7. References
6 WEC (2004). Total Energy Use Characteristics, of Global Transport and Energy
Development: The Scope for Change, WEC. (http://www.worldenergy.org,
December 2004)
7 ECPI; 2001. ECO PROFILE of high volume commodity phthalate esters. ECPI.
European Council for Plasticizers and Intermediates.
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Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
4
Energy consumption and CO2 emission; production, use and final disposal of PVC, XLPE and PE cables with mineral charge
TABLE XIV – 4
MAXIMUM ADMISSIBLE INTENSITIES IN AMPERES FOR INSULATED COPPER CONDUCTORS
INSTALLATION
UNDER EMBEDDED SINGLE-POLE CONDUCTORS MULTI-POLE CONDUCTORS
TUBE
2 1
TWO-POLE
SINGLE-POLE TWO-POLE
TYPE OF CONDUCTOR
BY DIFFERENT TEMPERATURE: TABLE FC-1
TEMPERATURE OF CONDUCTORS: (PVC) 70ºC (XLPE) AND (EPR) 90ºC
CORRECTION FACTORS:
ETHYLENE PROPYLENE
ETHYLENE PROPYLENE
POLYVINYL CHLORIDE
POLYVINYL CHLORIDE
POLYETHYLENE
POLYETHYLENE
CROSS-LINKED
CROSS-LINKED
TYPE OF INSULATION