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BASF AktiengesellschaftBASF Aktiengesellschaft
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EcoEco--Efficiency Analysis Efficiency Analysis –– BASFBASFDavid R. Shonnard, Chemical Engineering, MTU David R. Shonnard, Chemical Engineering, MTU EcoEco--Efficiency Analysis Efficiency Analysis –– BASFBASFDavid R. Shonnard, Chemical Engineering, MTU David R. Shonnard, Chemical Engineering, MTU
Validated Validated EcoefficiencyEcoefficiency
AnalysisAnalysisMethodMethod
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SEEbalance®-analysis*
* being developed* being developed
Ecoefficiency-Analysis
Sustainable Development is based on three PillarsSustainable Development is based on three PillarsSustainable Development is based on three PillarsSustainable Development is based on three Pillars
Society
Ecology
Economy
Sustainable DevelopmentSustainable DevelopmentSustainable DevelopmentSustainable Development
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BASF AktiengesellschaftBASF Aktiengesellschaft
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What is EcoWhat is Eco--Efficiency Analysis?Efficiency Analysis?What is EcoWhat is Eco--Efficiency Analysis?Efficiency Analysis?
�� Method for the Method for the comprehensive assessment comprehensive assessment of products and of products and processes.processes.
�� Ecological and economic aspectsEcological and economic aspects are given equal weight in are given equal weight in assessments. assessments.
�� The products are analyzed from the The products are analyzed from the angle of the end angle of the end customercustomer..
�� (Future) scenarios (Future) scenarios and effects of various action options are and effects of various action options are presented.presented.
�� EcoEco--efficiency analysis is a efficiency analysis is a standard standard tool in the tool in the BASF GroupBASF Group; ; more than 170* analyses have been carried out.more than 170* analyses have been carried out.
* Status 12/2002* Status 12/2002
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A LifeA Life--Cycle View on Environmental ImpactsCycle View on Environmental ImpactsA LifeA Life--Cycle View on Environmental ImpactsCycle View on Environmental Impacts
LCA studies are conducted according to accepted international standards, ISO 14040 LCA studies are conducted according to accepted international standards, ISO 14040 –– 14043.14043.
Saling, P. et al., 2002, Int. Jour. LifeSaling, P. et al., 2002, Int. Jour. Life--Cycle Assessment, Vol. 7(4), 203Cycle Assessment, Vol. 7(4), 203--218.218.
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Main Stages in a LifeMain Stages in a Life--Cycle AssessmentCycle AssessmentMain Stages in a LifeMain Stages in a Life--Cycle AssessmentCycle Assessment
�� Definition of a Definition of a Functional UnitFunctional Unit
�� Compiling an Compiling an Inventory ofInventory of inputs into and outputs from a inputs into and outputs from a product system. product system.
�� Evaluating the potential Evaluating the potential Environmental ImpactsEnvironmental Impacts of the product of the product system. system.
��AA ClassificationClassification of impacts into categories (global warming, etc.)of impacts into categories (global warming, etc.)
��A A CharacterizationCharacterization of impacts using impact potentials (global of impacts using impact potentials (global warming potential, etc.)warming potential, etc.)
�� InterpretationInterpretation of results and an of results and an ImprovementImprovement analysis. analysis.
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Sources of Data for EcoSources of Data for Eco--efficiency Analysisefficiency AnalysisSources of Data for EcoSources of Data for Eco--efficiency Analysisefficiency Analysis
�� EmissionsEmissions from the consumption of electricity, fossil fuels, and from the consumption of electricity, fossil fuels, and raw materialsraw materials
��Academic research, government research and documents, Academic research, government research and documents, and commercial software databases.and commercial software databases.
�� Characterization FactorsCharacterization Factors are obtained from several sources. are obtained from several sources.
��Government documents, databases, and commercial Government documents, databases, and commercial software tools. software tools.
�� NormalizationNormalization data. We are often concerned about how large data. We are often concerned about how large the impacts are compared to some reference. A common the impacts are compared to some reference. A common reference is national impact data (USA, EU, Japan, etc.)reference is national impact data (USA, EU, Japan, etc.)
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Energy consumption
Raw materialconsumption
Area requirement
Emissionen
Toxicity potential
Risk potential
Emissionen
Environmental Impact Categories Environmental Impact Categories Environmental Impact Categories Environmental Impact Categories
Emissions
Luft-emissionen
50%
Wateremissions
35%
Wastes15%
Luft-emissionen
50%
Airemissions
50%
Greenhousewarming potential
Ozone depletionpotential
Photochemicalozone creation
potential
Acidification potential
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Energy consumption
Raw materialconsumption
Area requirement
20%20%
20%20%
10%10%
20%20%
10%10%
20%20% Emissionen
Toxicity potential
Risk potential
Emissionen
Social Assessment Factors Social Assessment Factors Social Assessment Factors Social Assessment Factors
quantitative:quantitative:
Emissions
Luft-emissionen
50%
Wateremissions
35%
Wastes15%
Luft-emissionen
50%50%50%
20%20%
20%20%
10%10%
Airemissions
50%
Greenhousewarming potential
Ozone depletionpotential
Photochemicalozone creation
potential
Acidification potential
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BASF AktiengesellschaftBASF Aktiengesellschaft
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Jeans Dyeing Jeans Dyeing ProjectProject
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Determine demandDetermine demand--specific benefitspecific benefit
Dyeing of blue
denim for the
production of
1000 jeans
Define comparableDefine comparableproductsproducts
Select BASFSelect BASFproductproduct
synthetical
indigo
granules
Indigo powder from plants
Alternative Systems for Indigo GranulesAlternative Systems for Indigo GranulesAlternative Systems for Indigo GranulesAlternative Systems for Indigo Granules
biotechnological Indigo granules
synthetical indigo solution,40%,
synthetical lndigo solution, 40%,electrochemical dyeing process
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The detailed Results can be read off in the The detailed Results can be read off in the Environmental FingerprintEnvironmental FingerprintThe detailed Results can be read off in the The detailed Results can be read off in the Environmental FingerprintEnvironmental Fingerprint
Energy consumptionEnergy consumption
ToxicityToxicitypotentialpotential
RiskRiskpotentialpotential
EmissionsEmissions
MaterialMaterialconsumptionconsumption
Powder Powder from plantsfrom plants
0,00,0
0,50,5
1,01,0
Granules,Granules,biotechnobiotechno--logicallylogically
Granules, Granules, syntheticallysynthetically
Solution, Solution, 40%40%
Solution, Solution, electroelectro--chemicallychemically
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In the EcoIn the Eco--Efficiency Portfolio, the Environmental Efficiency Portfolio, the Environmental Impact is plotted against the CostsImpact is plotted against the CostsIn the EcoIn the Eco--Efficiency Portfolio, the Environmental Efficiency Portfolio, the Environmental Impact is plotted against the CostsImpact is plotted against the Costs
Benefit:
1.000 jeans
dyed with
indigo
BASF indigo(synthetic)
Indigo powder from
plants
Indigo(biotechnologically)
BASF indigo vat solution40%
(dyed traditionally)
BASF indigo vat solution40%
(dyed electrochemically)
0.4
1.0
1.6
0.41.01.6
Total costs (normalized)
En
vir
on
me
nta
l im
pac
t (n
orm
ali
ze
d)
Low eco-efficiency
High eco-efficiency
13
4
5
2
1
2
3
4
5
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Consequences of the AnalysisConsequences of the AnalysisConsequences of the AnalysisConsequences of the Analysis
�� Construction of a plant for the production of 40% indigo solution Construction of a plant for the production of 40% indigo solution
(beginning production at the end of 1999)(beginning production at the end of 1999)
�� Increased R&D expenditure for the electrochemical process Increased R&D expenditure for the electrochemical process
(construction of a pilot plant)(construction of a pilot plant)
�� Communication with customersCommunication with customers
��Success of the measures: Increase of the market share Success of the measures: Increase of the market share from 2% (1999) to approximately 40% (2002)from 2% (1999) to approximately 40% (2002)
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Determine demandDetermine demand--specific benefitspecific benefit
Coating of
1000 wooden
front doors to
the performance
specification.
Other Coating TechnologiesOther Coating TechnologiesSelect BASFSelect BASFproductproduct
uv cured
coating
technology
polyurethane
Alternative Systems for Industrial CoatingsAlternative Systems for Industrial CoatingsAlternative Systems for Industrial CoatingsAlternative Systems for Industrial Coatings
acid curing
nitrocellulose
Water based coating
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LifeLife--Cycle Costs of Alternative CoatingsCycle Costs of Alternative CoatingsLifeLife--Cycle Costs of Alternative CoatingsCycle Costs of Alternative Coatings
0
1000
2000
3000
4000
UV-system Aqueous
system
2 C-PU
system
AC-system NC-system
Co
sts
[€/u
ser
ben
efi
t]Primer Coating Stain Machinery Personnel costs Energy
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EcoEco--Efficiency Portfolio, CoatingsEfficiency Portfolio, CoatingsEcoEco--Efficiency Portfolio, CoatingsEfficiency Portfolio, Coatings
Customerrelatedbenefit: Coating of 1000 wooden doors with asemi gloss, transparent texture
Aqueous varnish
UV-varnish
2 C-PU varnish
AC-varnish
NC-varnish
The base case shows the UV-varnish as the most ecoefficientalternative
0,1
1,0
1,9
0,11,01,9
Total costs (normalised)
En
vir
on
men
tal im
pacts
[no
rmali
zed
]
UV
2C-PU
Aqua.
AC NC
Base case
Customerrelatedbenefit: Coating of 1000 wooden doors with asemi gloss, transparent texture
Customerrelatedbenefit: Coating of 1000 wooden doors with asemi gloss, transparent texture
Aqueous varnish
UV-varnish
2 C-PU varnish
AC-varnish
NC-varnish
Aqueous varnish
UV-varnish
2 C-PU varnish
AC-varnish
NC-varnish
The base case shows the UV-varnish as the most ecoefficientalternative
The base case shows the UV-varnish as the most ecoefficientalternative
0,1
1,0
1,9
0,11,01,9
Total costs (normalised)
En
vir
on
men
tal im
pacts
[no
rmali
zed
]
UVUV
2C-PU
Aqua.
2C-PU
Aqua.
AC NCAC NC
Base case
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BASF AktiengesellschaftBASF Aktiengesellschaft
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Scenario Analysis:Scenario Analysis:Scenario Analysis:Scenario Analysis:
Customerrelatedbenefit: Coating of 1000 wooden
doors with asemi gloss, transparent texture
Aqueous varnish
UV-varnish
2 C-PU varnish
AC-varnish
NC-varnish
In this scenario
the UV- coating isstill the mosteccoefficientalternative
0,1
1,0
1,9
0,11,01,9
Total costs (normalised)
En
vir
on
me
nta
l im
pa
cts
[no
rma
lize
d]
UV
Aqua.
AC NC
Scenario: Doubling the Irradiation Energy for the UV-varnish
2C-PU
UVCustomerrelatedbenefit: Coating of 1000 wooden
doors with asemi gloss, transparent texture
Customerrelatedbenefit: Coating of 1000 wooden
doors with asemi gloss, transparent texture
Aqueous varnish
UV-varnish
2 C-PU varnish
AC-varnish
NC-varnish
Aqueous varnish
UV-varnish
2 C-PU varnish
AC-varnish
NC-varnish
In this scenario
the UV- coating isstill the mosteccoefficientalternative
In this scenario
the UV- coating isstill the mosteccoefficientalternative
0,1
1,0
1,9
0,11,01,9
Total costs (normalised)
En
vir
on
me
nta
l im
pa
cts
[no
rma
lize
d] 0,1
1,0
1,9
0,11,01,9
Total costs (normalised)
En
vir
on
me
nta
l im
pa
cts
[no
rma
lize
d]
UVUV
Aqua.
AC NCAC NC
Scenario: Doubling the Irradiation Energy for the UV-varnish
2C-PU
UV
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Determine demandDetermine demand--specific benefitspecific benefit
Other Coating TechnologiesOther Coating TechnologiesSelect BASFSelect BASFproductproduct
2. PET, 1.5 L, case of 6
Mineral Water Beverage Packaging StudyMineral Water Beverage Packaging StudyMineral Water Beverage Packaging StudyMineral Water Beverage Packaging Study
3. Glass, 0.7 L, case of 12
4. PET, 1.5 L, case of 6, use once, 56% return rate
5. PET, 1 L, case of 6, use once, 56% return rate
1.
PET bottle, 1 L,
reusable 15 times,
recycle to textile
industry, case of
12, refundable
deposit, return
rate of 95%
Marketing of
1000 liters of
mineral water in
a perimeter of
200 kilometers
from the
production site
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BASF AktiengesellschaftBASF Aktiengesellschaft
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EcoEco--Efficiency Portfolio, Beverage PackagingEfficiency Portfolio, Beverage PackagingEcoEco--Efficiency Portfolio, Beverage PackagingEfficiency Portfolio, Beverage Packaging
0,2
1,0
1,8
0,21,01,8
Total costs (normalized)
En
vir
on
men
tal im
pacts
(n
orm
alized
)
PET, 12 x 1 liter,depositPET, 6 x 1.5 liter,depositGlass, 12 x 0.7 liter,depositPET, 6 x 1 liter, nodepositPET, 6 x 1.5 liter, nodeposit
Customerbenefit: Marketing of 1000 liters of mineral water in a perimeter of 200 km for the house-hold
market.
Customerbenefit: Marketing of 1000 liters of mineral water in a perimeter of 200 km for the house-hold
market.
The PET reusable 1 liter bottle and the PET recyclable 1.5 liter bottle are the most eco-efficient
The PET reusable 1 liter bottle and the PET recyclable 1.5 liter bottle are the most eco-efficient
High Eco-efficiency
Low Eco-efficiency
High Eco-efficiency
Low Eco-efficiency
1
3
4
2
5
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What does BASF use EcoWhat does BASF use Eco--Efficiency Efficiency Analysis for?Analysis for?What does BASF use EcoWhat does BASF use Eco--Efficiency Efficiency Analysis for?Analysis for?
InternalInternal
ExternalExternal
Politics
• Discussion with opinion makers in political decisions
Strategy
• Decisions on investments
Marketing
• External customers optimize their products and processes with eco-efficiency analyses
Research/product development
• Prioritization of research projects
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Consequences of EcoConsequences of Eco--Efficiency AnalysesEfficiency AnalysesConsequences of EcoConsequences of Eco--Efficiency AnalysesEfficiency Analyses
costscosts (normalized)(normalized)
Environmental Impact Environmental Impact (normalized)(normalized)
1,01,0
1,01,0highhigh lowlowhighhigh
lowlow
Depending on the position of the analysed product, different strategical recommen-dations are given.
Bring to market!Bring to market!
reduce reduce environmental environmental impact!impact!
Develop Develop alternatives!alternatives!
reduce reduce costs!costs!
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Acceptance of the Method by Stakeholders, Acceptance of the Method by Stakeholders, NGOs and Science ...NGOs and Science ...Acceptance of the Method by Stakeholders, Acceptance of the Method by Stakeholders, NGOs and Science ...NGOs and Science ...
Dr. Reinhard LoskeMitglied des Deutschen BundestagesUmweltpolitischer Sprecher Bündnis 90/DIE GRÜNEN
Öko-Institut e.V.;Bereiche Chemie und Umweltrecht
...Basically, the large number of indicators used in eco-efficiency analysis make relatively reliable statements possible ...
......Politically, it is worth considering how this tool can find wider application.......
....The sensitivity considerations carried out in the eco-efficiency analysis make sense and provide good orientation as regards further ecological and economic optimizations....
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... and the whole World.... and the whole World.... and the whole World.... and the whole World.
Pilot project with UNEP/UNIDO to improve the eco-efficiency of Moroccan dyehouses
Assessed since 2002 as one of the world’s most sustainable chemical companies, partly as the result of the development of eco-efficient products
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Germany PicturesGermany PicturesGermany PicturesGermany Pictures
BASF Ludwigshafen:Global Headquartersand worlds largestintegrated productionfacility.
Badische Anilin & Soda FabrikFounded April 6, 1865in Ludwigshafen byFriedrich Engelhorn
Global Data89,000 employees$32 billion annual sales
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Ludwigshafen SiteLudwigshafen SiteLudwigshafen SiteLudwigshafen Site
BASF Ludwigshafen:7 km2, 300 productionsites, 8000 products,39,000 employees.
Eco-efficiency AnalysisGroup, Z570
ApartmentEschenbach Strasse 8,Ludwigshafen, DE
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Hochhaus (High House)Hochhaus (High House)Hochhaus (High House)Hochhaus (High House)
BASF Ludwigshafen:administration.
Across the street, First high pressure ammonia reactor,1909.
Haber-Bosch process
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Bldg Z570, EE, ToxicologyBldg Z570, EE, ToxicologyBldg Z570, EE, ToxicologyBldg Z570, EE, Toxicology
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EcoEco--efficiency Analysis Groupefficiency Analysis GroupEcoEco--efficiency Analysis Groupefficiency Analysis Group
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Some Skiing in Champrey, SwitzerlandSome Skiing in Champrey, SwitzerlandSome Skiing in Champrey, SwitzerlandSome Skiing in Champrey, Switzerland
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Heidelburg, Castle Ruins and Neckar RiverHeidelburg, Castle Ruins and Neckar RiverHeidelburg, Castle Ruins and Neckar RiverHeidelburg, Castle Ruins and Neckar River
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Almond Tree Festival, GimmeldingenAlmond Tree Festival, GimmeldingenAlmond Tree Festival, GimmeldingenAlmond Tree Festival, Gimmeldingen
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Smart Car (Mercedes Benz / Swatch)Smart Car (Mercedes Benz / Swatch)Smart Car (Mercedes Benz / Swatch)Smart Car (Mercedes Benz / Swatch)
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Examples of Fachwerkhaus ConstructionExamples of Fachwerkhaus ConstructionExamples of Fachwerkhaus ConstructionExamples of Fachwerkhaus Construction
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Neuschwanstein and HohenschwangauNeuschwanstein and HohenschwangauNeuschwanstein and HohenschwangauNeuschwanstein and Hohenschwangau