LCA in the Automotive Sector. Russ Balzer Technical Director, WorldAutoSteel

“LCA in the Automotive Sector” Russ Balzer Technical Director, WorldAutoSteel WorldAutoSteel Automotive Group of the World Steel Association MEMBER...
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“LCA in the Automotive Sector” Russ Balzer Technical Director, WorldAutoSteel

WorldAutoSteel

Automotive Group of the World Steel Association MEMBER COMPANIES: Ansteel Arcelor Mittal Baosteel China Steel JFE JSW Steel Hyundai Steel Kobe Nippon Steel & Sumitomo

Nucor POSCO Severstal SSAB Tata Steel ThyssenKrupp USIMINAS U. S. Steel voestalpine

In this Presentation

• • •

The problem with current regulations

The need for Life Cycle Thinking What is the Steel Industry Doing?

In this Presentation

• The problem with current regulations • •

The need for Life Cycle Thinking What is the Steel Industry Doing?

Tailpipe emissions standards are becoming more stringent across the globe

Source: International Council on Clean Transportation August 2011

The Tailpipe Approach

Fuel Production

Vehicle Production

Vehicle Use (Fuel Combustion)

Current Regulations

Vehicle End of Life

What are the Engineering Principles Behind Light-weighting? Q: How can car manufacturers reduce tailpipe GHG emissions? Let’s look at where the tractive power demand is coming from: 𝑃𝑡𝑟𝑎𝑐𝑡 = 𝒎𝑔𝑪𝑹𝑹 + 1 8 𝜌𝑪𝑫 𝑨𝑭 𝑉𝑖 + 𝑉𝑖+1 Rolling Resistance

Aerodynamic Drag

2

+ 𝒎𝒓 𝑉𝑖 + 𝑉𝑖+1 + 1 2 𝒎𝑔 sin 𝑞 𝑉𝑖 + 𝑉𝑖+1 Inertia acceleration

Inertia - grade

A: Manufacturers can:

• • • •

Reduce the aerodynamic drag coefficient and/or the frontal area

Reduce rolling resistance coefficient Increase the energy conversion efficiency of the drive train Reduce vehicle mass o vehicle mass shows up in 3 of the 4 power demand terms o vehicle mass can be reduced using low density materials

A Hole in the Tailpipe Approach

A Hole in the Tailpipe Approach Material Production GHG comparison for a functionally equivalent component - typical example Mid-Range CO2e

Estimated Part Weight (kg)

Mild Steel

2.3

100

AHSS

2.3

75

Aluminium

11.3

67

Magnesium

46.0

50

Carbon FRP

22.0

45

(kg CO2e) 230 173

757 2300

990

A Hole in the Tailpipe Approach An unintended consequence of tailpipe-only regulations Vehicle Production emissions Tailpipe emissions Cost Result: potential for overall higher GHG emissions at higher cost

What Does the Future Hold? Affect of increased powertrain efficiency and alternative fuels on carbon footprint

Battery electric vehicle

Fuel economy or tailpipe emissions standards are not enough to ensure overall reductions in automotive GHG emissions.

In this Presentation



The problem with current regulations

• The need for Life Cycle Thinking •

What is the Steel Industry Doing?

Life Cycle Assessment (LCA)

Source: worldsteel

Who Uses LCA? Automakers

Consumer Products Manufacturers

Material Producers

Industry Associations

In this Presentation

• • •

The problem with current regulations

The need for Life Cycle Thinking What is the Steel Industry Doing?

Including LCA in future regulations



What is the Steel Industry Doing?



Technical Programs





LCA Development





How can we help OEMs use steel more efficiently?

How can we help to develop LCA tools and methodologies?

LCA Policy



How can we convince regulators that LCA is the right way to go?

Including LCA in future regulations



What is the Steel Industry Doing?



Technical Programs





LCA Development





How can we help OEMs use steel more efficiently?

How can we help to develop LCA tools and methodologies?

LCA Policy



How can we convince regulators that LCA is the right way to go?

Technical Programs - FutureSteelVehicle

ULSAB UltraLight Steel Auto Body

ULSAC UltraLight Steel Auto Closures

ULSAS UltraLight Steel Auto Suspensions

Nature’s Way to Mobility ULSAB-AVC Advanced Vehicle Concepts

Technical Programs – FutureSteelVehicle

1. State-of-the-future development process

2. 177 kg body structure mass - 39% mass reduction 3. 97% use of HSS and AHSS

4. Nearly 50% GigaPascal steels 5. Enables 5-star safety ratings

6. Nearly 70%Total Lifetime Emissions Reduction 7. Mass savings at no cost penalty 8. Near-term production applicable solutions

Technical Programs – AHSS Application Guidelines

AHSS Guidelines version 5.0 • Significant changes since 2008: • steel industry consolidation • FSV deliverables • global vehicle regulations converging • Include FSV learnings • materials portfolio • fabrication methods • Significant joining upgrades

Including LCA in future regulations



What is the Steel Industry Doing?



Technical Programs





LCA Development





How can we help OEMs use steel more efficiently?

How can we help to develop LCA tools and methodologies?

LCA Policy



How can we convince regulators that LCA is the right way to go?

LCA Development - Automotive Materials Comparison Models • UCSB Automotive Materials Energy and GHG Comparison Model • Design Advisor • autoLCA

LCA Development – UCSB GHG Model • Full-vehicle model using peer-reviewed LCA methodology • GHG and Total Primary Energy

LCA Development – UCSB GHG Model

• 7 Powertrains 5 vehicle classes 3 driving cycles

• 2 Recycling Methodologies

MSR

CSE

LCA Development – UCSB GHG Model Fully parameterized and transparent End of Life Management of Vehicle

Conventional Steel Flat carbon steel Long & special steel Cast iron AHSS (ULSAB-AVC) Flat carbon steel Long & special steel Cast iron Aluminum Rolled aluminum Extruded aluminum Cast aluminum Composites SMC GFRP CFRP Magnesium Cast Mg Zirmax AZ91 Alloy Rolled Mg

Collection

Shredder

Material Recycling Recovery Rate

in %

in %

in %

in %

97% 97% 97%

98% 98% 98%

95% 95% 95%

90.3% 90.3% 90.3%

97% 97% 97%

98% 98% 98%

95% 95% 95%

90.3% 90.3% 90.3%

97% 97% 97%

90% 90% 90%

90% 90% 90%

78.6% 78.6% 78.6% 0.0% 0.0% 0.0%

97% 97% 97%

90% 90% 90%

90% 90% 90%

78.6% 78.6% 78.6%

LCA Development – Design Advisor • Vehicle system level analysis of component material options • Comparison of mass, cost, GHG emissions

LCA Development – Design Advisor • Multiple Secondary Mass Change methodologies

LCA Development – Design Advisor Sensitivity Analysis for Key Parameters Perturbed Performance

Comparison Base-line to Perturbed nominal vehicle -2 better

0

resized vehicle 2 better

nominal

1

resized

difference

20.00 18.00

18.00 16.00

1507

1505

40

96

3

% of nom

-2.00 -2.00 -0.60 -2.60

-10% -11%

56.08 -0.80 55.28 -5.27

140%

0%

5

7

11640

9

8988

11635 8984

0%

-4.07 50.01

11

51.21

• Built-in Sensitivity Analysis

13

15

17

19

21

Run Analysis

80 4462 4541 -38 -1869 -1907 34375 37010

260 4460 4720 0 -1868 -1868 34360 37212

180.94 -1.90 179.03 38.26 0.70 38.97 -15.56 202.43

227% 0% 4% -100% 0% -2% 0% 1%

+10% 0 -10%

Competitor component mass Nominal vehicle mass Vehicle mass compounding Fuel consumption mass sensitivity Fuel CO2/unit Material CO2/kg - Original Part Reset Material CO2/kg - Competitor Part parameter Recy cling Rate - Original Part Recy cling Rate - Competitor Part values Recy cling CO2/kg - Original Part Recy cling CO2/kg - Competitor Part

LCA Development - autoLCA™ • Importation of UCSB methodology into GaBi modeling software • Ganzheitliche Bilanz (“Holistic Balance”) • Connection to GaBi datasets – Standardized data – Full LCI data – GaBi is used globally

LCA Development - autoLCA™ • GaBi datasets – 4700 LCI (Lifecycle Inventory) Datasets – Database upgrades every year – Standardization of methods and boundaries across datasets

LCA Development - autoLCA™

As in the UCSB Model, GHG and Energy results are displayed by Life Cycle stage…

… and by driving distance.

LCA Development - Case Study in autoLCA™ Full Results CHARACTERIZATION RESULTS TRACI 2.1, Acidification Air [kg SO2-Equiv.] TRACI 2.1, Acidification Water [kg SO2-Equiv.] TRACI 2.1, Ecotoxicity (recommended) [CTUeco] TRACI 2.1, Eutrophication Air [kg N-Equiv.] TRACI 2.1, Eutrophication Water [kg N-Equiv.] TRACI 2.1, Global Warming Air [kg CO2-Equiv.] TRACI 2.1, Human Health Particulate Air [kg PM2,5-Equiv.] TRACI 2.1, Human toxicity, cancer (recommended) [CTUh] TRACI 2.1, Human toxicity, non-canc. (recommended) [CTUh] TRACI 2.1, Ozone Depletion Air [kg CFC 11-Equiv.] TRACI 2.1, Resources, Fossil fuels [MJ surplus energy] TRACI 2.1, Smog Air [kg O3-Equiv.]

Baseline Vehicle

AHSS intensive

Aluminium intensive

65.376

61.264

65.296

0.03975

0.03492

0.02712

13.486

12.091

9.501

2.3936

2.2510

2.2953

3.1806

2.9894

2.8841

33548

31597

32013

8.3776

7.8657

8.9710

1.7965E-07

1.6513E-07

2.1296E-07

3.1270E-08

2.9406E-08

3.0430E-08

7.8458E-05

6.6022E-05

4.2219E-05

60711

57349

57525

675.52

632.10

662.56

LCA Development - Partnerships Participation in key industry and environmental activities • International LCA/Sustainability Organizations – Participating in LCA advocacy and the development of LCA methodology • Worldwide conferences on LCA and Sustainability – Learning and sharing best practices • Leading Universities – Funding Automotive and LCA research

Including LCA in future regulations



What is the Steel Industry Doing?



Technical Programs





LCA Development





How can we help OEMs use steel more efficiently?

How can we help to develop LCA tools and methodologies?

LCA Policy



How can we convince regulators that LCA is the right way to go?

LCA Policy – Awareness to Deployment Engagement of Regulators

• • •

Current focus on EU Provide technical support

• •

Modeling tools LCA workshops

Push for inclusion of LCA in post-2020 regulations

LCA Policy – Awareness to Deployment Current State of Play

Final rule did not explicitly support LCA, but did cite its potential to account for production emissions relevant to future vehicles. USEPA will create an LCA Group to monitor development.

Recommendation made by Environment Committee to consider full LCA in post-2020 regulations removed from the recital, but recital does contain a recommendation that policy action take into account emissions associated with fuel/energy production.

In Conclusion • Current Tailpipe-only regulations ignore emissions from other aspects of a vehicle's life cycle and lead to an overemphasis on mass reduction. • Life Cycle Assessment takes into account all phases of a vehicle's life and gives a more comprehensive picture of a vehicle's environmental impact. • WorldAutoSteel is working with universities, our member companies, and the LCA community to develop the technologies, tools and methods needed for LCA to be used in vehicle emissions regulations. • WorldAutoSteel is working to educate regulators and lawmakers on the advantages of LCA as a regulatory tool, and to encourage them to include LCA in future emissions regulations.

LCA in the Automotive Sector

Thank You!

Questions? Please contact me at [email protected]