Life cycle inventory of the automotive paint processes

JCT CoatingsTech, June, 2008 by Lindita Prendi, Edwin K.L. Tam

Aggregated material/energy/emissions LCI process flow maps are useful in data source identification and also graphically represent the normalized LCI results. LCI process flow maps are recommended as a supplementary summary reporting format, particularly where LCI data is to be presented to management or in a public forum.

Manufacturing LCIs should be based on a data collection and reporting parameter that best represents the function and mechanisms of the transformation process; the selected parameter should be used for the functional unit and as the basis of data scaling. For the paint process, the "best practice" LCI data collection and reporting parameter should be the painted surface area.

Where the opportunity exists, the installation of additional electricity and water metering for paint shop facility processes can facilitate and improve LCI data collection. Additional metering is likely to be most cost-effectively added during the construction or renovation of any particular industrial facility.

Industry Application of Manufacturing LCI Data

LCI application protocols can be formulated to allow site-specific reference data, such as will be available from the NREL LCI Database, to be used for predicting LCI results for a different manufacturing facility/scenario.

If the selected functional unit is consistent with LCI principles in representing the function of the manufacturing transformation process, it will form the basis for scaling a reference LCI dataset to a different production facility or production scenario.

The NREL LCI paint dataset developed in this research should generally not be applied directly to an-other facility as a surrogate dataset. Aside from process differences between any two manufacturing facilities, differences in painted BIW surface area and differences in annual production volumes will affect the results. As a result, it will likely be necessary to use an appropriate scaling protocol when adapting one set of data to an independent facility.

References

(1) "U.S. LCI Database Project Research Protocol," Athena Sustainable Materials Institute, Athena Institute, Athena, 2001.

(2) Dobson, I.D, "Life Cycle Assessment for Painting Processes: Putting the VOC Issue in Perspective," Prog. Org. Coat., 27, 1-4, pp. 55-58 (1996).

(3) Matthias, H. and Manfred, S., "Life-Cycle Engineering of Powder Coating Technology in Comparison to Other Painting Technologies," Ph.D. Thesis, University of Stuttgart, 1996.

(4) Prendi, L., Henshaw, P., and Tam, E.K.L., "Automotive Coatings with Improved Environmental Performance," Intern. I. Environ. Studies, 63, 4, pp. 463-471 (2006).

(5) Tam, E.K.L. and Abdulrahem, F.I., "Preliminary Comparison of Conceptual Data versus Site Specific Data for Life Cycle Inventories," International CIRP Seminar on LCE, Grenoble, France, Laboratoire 3S, 2005.

(6) NREL, www.nrel.gov/lci, May 2005.

(7) NREL, www.nrel.gov/lci, March 2007.

(8) Bosch, A.G., Automotive Handbook, Robert Bosch GmBH, 2000.

(9) Papasavva, S., Kia, S., Claya, J., and Gunther, R., "Characterization of Automotive Paints: An Environmental Impact Analysis," Prog. Org. Coat., 43, pp. 193-206 (2001).