Life Cycle Assessment

Lecture 2
What is Life Cycle Assessment?
Life Cycle Assessment (LCA) is a standardized, systematic process for evaluating the
environmental impacts associated with a product, process, or service throughout its life cycle.
It is governed by international standards such as ISO 14040 and ISO 14044.

The LCA framework consists of four key phases:

1. Goal and Scope Definition
2. Life Cycle Inventory (LCI) Analysis
3. Life Cycle Impact Assessment (LCIA)
4. Interpretation

For manufacturing companies, conducting an LCA helps in identifying "hotspots" of

environmental impact, optimizing energy and material usage, and aligning with global
sustainability goals.
What is Life Cycle Assessment?
How is the LCA Process Initiated in a Manufacturing Company?

Step 1: Understanding the Need for LCA

Manufacturing companies begin the LCA process for multiple reasons:
─ Compliance with environmental regulations and policies.
─ Understanding the carbon footprint and other environmental impacts.
─ Achieving sustainability certifications like EPD (Environmental Product Declarations) or
Green Label Certifications.
─ Gaining a competitive advantage in sustainable manufacturing.
─ Meeting stakeholder expectations and reporting requirements (e.g., ESG reporting). A report
published by companies on the environmental, social, and governance (ESG) impacts of
their activities.
How is the LCA Process Initiated in a Manufacturing Company?

Step 2: Defining Goals and Scope

The first formal step in an LCA is defining the goal and scope of the study.
─ Goal Definition: Why is the LCA being conducted? Examples include reducing carbon footprint,
improving energy efficiency, or product optimization.
─ Scope Definition: Specifies system boundaries, functional unit, and assumptions.
─ System Boundary: This determines which stages of the life cycle are studied, for example,
Cradle-to-Gate, from raw material extraction to factory gate.
─ Cradle-to-Grave: Full life cycle, including use and disposal. Cradle-to-Cradle: Includes recycling
and circular economy aspects.
─ Functional Unit: A quantified measure of the product’s function. Example: "Producing 1,000 kg of
steel components."
Different Types of Scope
Framework Key Phases Included Focus
Entire life cycle, including Comprehensive analysis from
Cradle-to-Grave
disposal resource extraction to end-of-life
Cradle-to-Gate Extraction to leaving factory Focuses on production impacts
Cradle-to-Cradle Full life cycle + recycling/reuse Emphasis on circular economy
Extraction to the end of use
Cradle-to-Use Excludes end-of-life
phase
Cradle-to-End-of-Life Extraction to disposal/recycling Emphasizes end-of-life strategies
Cradle-to-Factory Extraction to factory assembly Stops at assembly stage
Cradle-to-Site Extraction to delivery at site Focuses on delivery phase
Extraction to readiness for Stops at the point the product is
Cradle-to-Service
providing service operational
Stops at installation phase, often
Cradle-to-Installation Extraction to installation relevant for construction
materials or equipment.
How is the LCA Process Initiated in a Manufacturing Company?

Step 3: Assembling the LCA Team

The team for conducting an LCA typically consists of:
1. LCA Expert / Sustainability Analyst: Leads the study, ensures adherence to ISO standards,
and conducts data analysis.
2. Process Engineers: Provide insights into manufacturing processes, raw materials, and energy
consumption.
3. Environmental Managers: Ensure regulatory compliance and alignment with corporate
sustainability goals.
4. Supply Chain Specialists: Analyze upstream and downstream processes, including raw
material extraction and transportation.
5. Data Analysts: Manage and process large datasets for inventory and impact calculations.
6. Project Manager: Coordinates timelines, budgets, and team collaboration.
How is the LCA Process Initiated in a Manufacturing Company?

Step 4: Data Collection and Inventory Analysis

The Life Cycle Inventory (LCI) phase is the most time-intensive. In this phase, data on all system
inputs and outputs are collected and quantified.
Key Data Categories Studied:
1. Raw Materials: Quantities and types of raw materials used. Environmental impact of raw
material extraction (e.g., mining emissions).
2. Energy Consumption: Electricity, fuel, and other energy sources are consumed at each stage.
3. Source of energy: Renewable vs. non-renewable.
4. Water Usage: Water consumption and wastewater generation.
5. Emissions: Greenhouse Gas (GHG) emissions (CO₂, CH₄, N₂O). Air, water, and soil pollutants.
6. Waste Generation: Solid waste, hazardous waste, and recycling processes.
7. Transportation: Logistics of raw materials, intermediate products, and final products.
8. Product Use and End-of-Life: Energy usage during product life, recyclability, and disposal.
Life Cycle Impact Assessment (LCIA)

In this phase, the collected inventory data is translated into environmental impacts. This involves:
─ Impact Categories:
─ Global Warming Potential (GWP) – measured in CO₂ equivalents.
─ Energy Demand – total energy consumed in the life cycle.
─ Water Footprint – total water used.
─ Eutrophication – impacts on water bodies due to nutrient emissions.
─ Resource Depletion – consumption of natural resources.
─ Characterization Models: Assign weights to environmental flows (e.g., carbon emissions vs. methane
emissions).
─ Example Tools for LCIA:
─ SimaPro
─ GaBi
─ OpenLCA
Case Study:
Life Cycle Assessment of Steel Components in Manufacturing

Overview of the Case Study

─ A mid-sized manufacturing company producing steel components for the
automotive sector initiated an LCA to measure its environmental impacts and
identify areas for improvement. The study used a Cradle-to-Gate approach and
analyzed 1,000 kg of steel components as the functional unit.
─ Team Involved:
─ LCA Expert
─ Process Engineers
─ Environmental Managers
─ Data Analysts
Case Study:
Life Cycle Assessment of Steel Components in Manufacturing

Goal and Scope:

─ Goal: Reduce carbon emissions and improve energy efficiency in steel production.
─ Scope: Cradle-to-Gate, including raw material extraction, transportation, and production.
Data Collection (Life Cycle Inventory):
Stage Data Collected Raw Material Extraction 1,800 kg iron ore per 1,000 kg of steel components Energy
Consumption 2,500 kWh electricity; 500 liters of diesel (fossil fuel) Water Usage 1,200 liters for cooling
and production Emissions 1.9 metric tons of CO₂; 50 kg SO₂; 30 kg NOx Waste Generation 200 kg solid
waste; 50 kg hazardous waste Transportation 500 km (diesel-powered trucks)
LCIA Results:
1. Global Warming Potential (GWP): Total CO₂ equivalent emissions: 2.5 metric tons per 1,000 kg of
steel components.
2. Energy Demand: Total energy consumed: 2,500 kWh (50% from fossil fuels).
3. Water Usage: Total water footprint: 1,200 liters.
4. Hotspot Identification: Iron ore extraction and energy consumption during steel manufacturing
contributed 75% of total emissions.
Case Study:
Life Cycle Assessment of Steel Components in Manufacturing

Recommendations:
1. Energy Efficiency: Transitioning 40% of energy consumption to renewable sources.
2. Process Optimization: Improve smelting efficiency to reduce energy usage.
3. Raw Material Substitution: Use recycled steel to reduce emissions by 30%.
4. Water Management: Implement closed-loop water systems to reduce water
consumption by 50%.
Real-World Example: Volkswagen’s LCA for
Electric Vehicles
Volkswagen conducted an LCA for their ID.3 electric vehicle to compare
environmental impacts against internal combustion engine vehicles.
Key Findings:
─ The production phase of the ID.3 had higher emissions (due to battery production)
but was offset by significantly lower emissions during the use phase.
─ Over a 200,000 km life cycle, the ID.3 emitted 17% less CO₂ compared to a diesel-
powered car when powered by a European grid mix.
─ By switching to renewable energy during production, emissions could be reduced
further by 25%.
─ This case underscores the importance of analyzing life cycle phases
comprehensively and implementing targeted strategies.
Conclusion
─ Implementing Life Cycle Assessment in a manufacturing company is a structured, data-driven process that
empowers organizations to achieve sustainability goals.

─ By identifying hotspots, optimizing resource use, and reducing environmental impacts, LCA drives both
operational efficiency and environmental responsibility.

─ With growing regulatory pressures and market expectations for sustainable practices, LCA is no longer
optional but a critical tool for manufacturers to remain competitive and contribute to a cleaner future.

─ Key Takeaways:
─ LCA involves goal setting, data collection, impact analysis, and interpretation.
─ The LCA team includes LCA experts, engineers, and environmental managers.
─ A systematic LCA can identify carbon, water, and energy hotspots.
─ Real-world examples, like steel production or electric vehicles, highlight LCA's value.

─ By adopting LCA, manufacturing companies can pave the way for innovation, sustainability, and long-term
business growth.
Nature of Life Cycle Networks
─ Ethanol from corn is considered a renewable alternative to
gasoline due to its plant-based feedstock.
─ Corn ethanol uses CO₂ during growth, creating a "closed CO₂
loop" that reduces net greenhouse gas emissions compared to
gasoline.
─ From a narrow perspective, corn ethanol appears environmentally
friendlier due to reduced fossil energy use and emissions.
─ A broader analysis reveals that producing ethanol still relies
heavily on fossil energy, leading to greenhouse gas emissions.
Nature of Life Cycle Networks
Key steps involving fossil energy use in the ethanol supply chain include:

─ Transportation of ethanol by diesel-powered trucks.

─ Conversion of corn into ethanol using coal or natural gas energy.
─ Farming operations (planting and harvesting) using diesel-powered
machinery.
─ Production of fertilizers and pesticides from natural gas and fossil
resources.
─ Manufacturing of equipment for farming, transportation, and ethanol
production.
Nature of Life Cycle Networks
Life cycle analysis highlights that corn ethanol still depends on substantial fossil energy throughout
its life cycle.
─ Assuming corn ethanol is completely independent of fossil energy is overly simplistic and
incorrect.
─ Life cycle thinking also applies to vehicle energy use, considering direct and indirect energy
contributions:
─ Fuel burned during operation.
─ Energy needed to extract, refine, and transport fuel.
─ Energy to manufacture the vehicle.
─ Energy to build and maintain roads.
─ Energy to maintain auto-related services (repair shops, regulations, traffic systems, etc.).
─ Energy for healthcare associated with vehicle accidents and related health issues.
Nature of Life Cycle Networks
─ Indirect energy use (beyond fuel consumption) is significant in
determining total energy use for mobility.
─ A holistic analysis should account for:
─ Resource use (e.g., water, land, minerals).
─ Emissions (e.g., carbon dioxide, reactive nitrogen, toxic
chemicals).
─ Total resource use or emissions, often referred to as the
"footprint" or "life cycle flow," is crucial to avoid shifting
environmental impacts to other life cycle stages.
Nature of Life Cycle Networks
Goal Definition and Scope
─ The goals of sustainability assessment are often to choose between alternative options
and/or to identify opportunities for improving a product or steps in a life cycle.
─ Understanding and defining the goal of a life cycle study is essential for its proper
formulation and execution.
─ For example, the goal in comparing gasoline with ethanol may be to choose between
them from the perspective of mobility
─ While the goal in comparing grocery sacks could be to determine the best way of
transporting groceries.
─ After determining such a common functional unit for the comparison, the quantity of
each item may be calculated for a fair comparison.
─ This is illustrated by the following examples.
Goal Definition and Scope
Life Cycle Boundary
─ Another decision required for a life cycle study is about the scope of the study as defined by the
boundary of the network.
─ Capture all the direct and indirect resource flows in a life cycle, the network may need to be very
large.
─ Capturing such a large network may not be practically feasible owing to challenges in obtaining
data about each process in the network and to the resulting cost and computational intractability.
─ We will consider different ways of approximating the analysis boundary.
─ These approaches are illustrated in Figure 8.3 and described below.
─ Here, the full life cycle without any approximation consists of all the nodes in Figure 8.3a.
Life Cycle Boundary