master thesis seminar" carbon footprint of pultruded composite products in automotive...

Carbon footprint of pultruded composite products in Automotive applications: case study side panel

of a coach

Samer Ziadeh25.8.2015

Outline Introduction The aim of the case study Life cycle of the side panel The modeling and calculations Results and discussion Further work for improvements Conclusion

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Introduction• The increasing demands of the environmental protection

especially in the automotive industry.• The automotive industry is a major contributor of emitted

greenhouse gas emissions in the world.

03.05.2023Carbon trust, Carbon Footprinting guide- Carbon Trust, 2012.

3

”A carbon footprint is the total greenhouse gas (GHG) emissions caused directly and indirectly by an individual, organization, event or product, ”Carbon trust

o Kyoto GHG emissions: (CO2), (CH4), (N2O), (HFCs), (PFCs), (SF6).

o Carbon dioxide equivalent (CO2e) is a measure used to compare the emissions from various greenhouse gases based upon their global warming potential

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Emission factor CO2e

Activity data

mass/volume/energy/distance

CF of the given

activity

Standards and Labels Standards: PAS 2050, ISO/TS 14067, The GHG

Protocol: A corporate Accounting and Reporting Standard.

Labels:

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The aim of the case study• Calculating the CF and energy consumption for a

pultruded composite profile.• Comparing the values with other conventional materials.• Emphasize the benefits of light materials in weight

reduction, less fuel consumption and lower impacts on environment.

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The side panel of a coach

03.05.2023Exelcomposites.com, 'Exel Composites –

Advanced Pultrusion and Pullwinding Technologies', 2015.

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(a) The Body component fixed on coach, Solidworks drawing of the panel (b) front and (c) back

The pultruded composite profile is 43,2% wt of E-glass fiber (GF) and unsaturated polyester resin (UP).

Pultruded profiles enviromental analysis

03.05.2023J. Anderson, Green guide to composites, Garston: BRE; Netcomposites, 2004. 8

Sandwich panel 8m x 1m(25mm core) ribs as a core materials

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Fibers for Pultrusion (CSM with glass rovings) (39%)Polyester + 50% CaCO3 (45%)Closed mixing-any matrix (<1%)Pull fibers through resin - emissions from resin bath (15%)Cure through heated die (<1%)Saw to length (<1%)Cleaning of pultrusion machine (<1%)

Life cycle of side panel

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Data collection

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Materials Thickness (mm)

Density (kg/m3)

Weight (kg)

Stainless steel, ferritic, AISI 405, wrought, annealed, low nickel

0,9 7,82x103 64,74

Aluminium, 5005, wrought, H14 2,5 2,72x103 62,56

Carbon steel, AISI 1050, annealed 0,75 7,9x103 54,51

E-glass fiber/polyester, pultruded profile (UD fiber and CSM) 90̊ direction

3 1,9x103 52,44

Eco Audit modeling

03.05.2023Cambridge Engineering Selector Software (CES 2015). Granta desgin, 2015.

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CF and energy consumption calculationso Transportation phase: 4500 km distance

o Use phase: product life cycle 12 years, distance 200 km per day, usage 350 days per year

Life distance 840000 km

03.05.2023M. Ashby. Materials and environment. 2end

ed. Elsevier,2013. 13

Results and discussion

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Raw materials ex-traction

Manufacturing Transportation Use of the product End-of-life0

20000

40000

60000

80000

100000

120000

140000

160000

180000

9680

25100

168000

4050

174000

Energy Consumption MJ

Composite Aluminium Stainless steel Steel

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Raw materials extrac-tion

Manufacturing Transportation Use of the product End-of-life0

2000

4000

6000

8000

10000

12000

14000

507

10000

1650

11900

237

12400

CO2 footprint kg


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Total Carbon Footprint (kg)0

2000

4000

6000

8000

10000

12000

1400010600 10800

Composite AluminiumStainless steel Steel

Total Energy Consumption (MJ)0

20000400006000080000

100000120000140000160000180000200000

152000 153000

Composite AluminiumStainless steel Steel

The equivalent annual environmental burden (averaged over 12 year of a product life)

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12700

1620015100

12800

Total energy consumptions per a year (MJ/year)


885

11401080

900

Total CO2 footprint per a year (kg/year)

Transportation phase case scenarios

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Case scenario 1 (Truck-diesel)

Case scenario 2 (air flight -kerosene)

0100020003000400050006000700080009000

10000

278

7080

332

8450

344

8750

286

7270

Energy Consumption (MJ)

Composite Panel Aluminium PanelStainless steel Panel Steel Panel

Case scenario 1 (Truck-diesel)

Case scenario 2 (Air flight- kerosene)

0

100

200

300

400

500

600

700

19.8

474

23.6

566

24.4

586

20.3

487

CO2 footprint (kg)

Composite Panel Aluminium PanelStainles steel Panel Steel Panel

o Case 1: Effect of the transportation is a minor contributor to the total impacts with only >1% of the prodcut CF

o Case 2 : High impact of transportation in the air flight type with both energy and CO2 footprint.

Use phase case scenarios

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a-Dies

el-fam

ily ca

r

b-Gas

oline

-family

car

c- Elec

tric-fa

mily ca

r0

50000100000150000200000250000

Energy Consumption (MJ)


a-Dies

el-fam

ily ca

r

b-Gas

oline

-family

car

c-Elec

tric-fa

mily ca

r0

4000

8000

12000

16000

CO2 footprint (kg)


Further work for improvements A. Biocomposite:less CO2 emissions, lower embodied energy of materials, ease depletion of non-renewable resources and the possibility for biodegradation taking place as an end-of-life option.B. Material recyclingC. Chemical recycling methodD. Co-processing

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European Composites Industry Association (EuCIA ), "Composites Recycling Made Easy,"

EuCIA , 2011. 20

Conclusion• The use phase of the vehicle shows the most significant

enviromental impact emissions of the entire life cycle of the panel.

• By using composite materials, the use phase emissions from a vehicle were reduced due to lower weight/improved performance of composites.

• Implementing the recycling methods: (pyrolysis-hydrolysis-chemical recycling-biodegradation) at the end of life phase.

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Acknowledgement

Prof. Jyrki Vuorinen

Mikko Lassila, Kim Sjödahl, Eric Moussiaux

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Thank you for kind attention

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