A Life Cycle Assessment of the PureCell Stationary Fuel Cell System ...

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Table of Contents Executive Summary .......................................................................................................... 1 Acknowledgements ........................................................................................................... 2 Table of Contents .............................................................................................................. 3 List of Figures .................................................................................................................... 6 List of Tables ..................................................................................................................... 8 Chapter 1 – Introduction................................................................................................ 11 Chapter 2 - Procedures ................................................................................................... 13 LCA Software ............................................................................................................... 13 Data Collection ............................................................................................................. 13 Allocation Procedures ................................................................................................... 13 Impact Assessment........................................................................................................ 14 Chapter 3 - Goal and Scope ........................................................................................... 15 Goal of the Study .......................................................................................................... 15 Function and Functional Unit ....................................................................................... 15 System Boundaries........................................................................................................ 16 Manufacturing Phase ........................................................................................................................ 16 Use Phase ........................................................................................................................................... 17 End-of-Life Phase.............................................................................................................................. 19 SimaPro System Boundaries ............................................................................................................ 19 Chapter 4 - Inventory Analysis ...................................................................................... 20 Flow Diagram ............................................................................................................... 20 Inventory Tables ............................................................................................................................... 21 Steel Data ........................................................................................................................................... 21 Processing Data ................................................................................................................................. 21 Manufacturing Phase ........................................................................................................................ 21 Air blower ...................................................................................................................................... 23 Air valve subassembly .................................................................................................................... 24 Cabinet ventilation fan ................................................................................................................... 24 Cell stack shipping bracket ............................................................................................................ 25 Condenser ...................................................................................................................................... 25 Cell Stack Assembly (CSA) ............................................................................................................. 25 Electrical Control System (ECS) .................................................................................................... 29 Enclosure ....................................................................................................................................... 30 Frame ............................................................................................................................................. 30 Fuel compartment ventilation fan .................................................................................................. 31 Harnesses and cables ..................................................................................................................... 31 Integrated Low-temperature Shift converter (ILS) ......................................................................... 32 Misc. small parts ............................................................................................................................ 33 Power Conditioning System (PCS)................................................................................................. 34 Piping ............................................................................................................................................. 34 Piping insulation ............................................................................................................................ 35 Reformer ......................................................................................................................................... 35 Steam ejector .................................................................................................................................. 36 Thermal Management System (TMS) ............................................................................................. 36 Water Treatment System (WTS) ..................................................................................................... 37 Scrap Rates ........................................................................................................................................ 37 Steel scrap ...................................................................................................................................... 38 Copper scrap .................................................................................................................................. 39 3
Use Phase ........................................................................................................................................... 40 PureCell System Installation ...................................................................................................... 40 Electricity Generation .................................................................................................................... 41 PureCell System Maintenance .................................................................................................... 43 End-of-Life Phase.............................................................................................................................. 44 Chapter 5 - Impact Assessment and Interpretation .................................................... 46 Impact and Damage Categories .................................................................................... 46 Impact Assessment Steps .............................................................................................. 47 PureCell System LCA Results and Interpretation .................................................... 48 PureCell System Life Cycle LCA Results ................................................................................... 48 PureCell System Use Phase LCA Results ................................................................................... 51 PureCell System Manufacturing Phase LCA Results ................................................................ 53 PureCell System CSA (Cell Stack Assembly) LCA Results ...................................................... 57 PureCell System LCA Results without Allocated Energy Use for CSA Production ............... 61 Contribution and Sensitivity Analysis .......................................................................... 64 Contribution Analysis ....................................................................................................................... 65 Sensitivity Analysis ........................................................................................................................... 67 Eco-indicator 99 Robustness Analysis ............................................................................................. 70 Sensitivity Analysis for Assumptions .............................................................................................. 71 Conclusions ................................................................................................................... 75 Chapter 6 - Opportunities and Implementation in LCA ............................................ 77 Renewable Hydrogen from Wind Energy ..................................................................... 77 System Description ............................................................................................................................ 77 Inventory Tables ............................................................................................................................... 79 Results ................................................................................................................................................ 83 100 Miles Transport Scenario ........................................................................................................ 83 1000 Miles Transport Scenario ...................................................................................................... 86 Conclusions ........................................................................................................................................ 88 Alternative End-of-Life Scenario ................................................................................. 89 Changes in SimaPro Model .............................................................................................................. 89 Results ................................................................................................................................................ 92 Conclusions ........................................................................................................................................ 94 Chapter 7 - Final Conclusions ....................................................................................... 96 References ........................................................................................................................ 99 Appendices ..................................................................................................................... 101 Appendix A: PureCell System Manufacturing Phase Aggregated Inventory Table102 Appendix B: PureCell System Use Phase Inventory Tables................................... 104 Appendix C: PureCell System End-of-Life Phase Inventory Table ....................... 105 Appendix D: PureCell System Processes Imported in SimaPro ............................. 106 Steel cold rolled coil IISI [8] ............................................................................................................106 Stainless Steel 304 2B IISI [8] .........................................................................................................107 Stainless Steel 316 2B IISI [8] .........................................................................................................109 Graphite PureCell system [15] ....................................................................................................110 Electric Components PureCell system [16] ................................................................................111 MI250 Inverter [16] .........................................................................................................................111 Semiconductor chip PureCell system [17] .................................................................................117 Semiconductor wafer PureCell system [17] ...............................................................................117 Silicon wafer PureCell system [17] .............................................................................................119 Electric motor PureCell system [11] ...........................................................................................119 Aluminum (primary) produced in the USA [6] .............................................................................120 Platinum recycled PureCell system [13] .....................................................................................122 Activated carbon PureCell system [20] ......................................................................................122 4
Page 1 and 2: Report No. CSS06-09 June 30, 2006 A
Page 3 and 4: Document Description A Life Cycle A
Page 5: Acknowledgements This research was
Page 9 and 10: List of Figures Figure 3-1: Manufac
Page 11 and 12: List of Tables Table 4-1: Air blowe
Page 13 and 14: Table 0-12: Semiconductor chip Pure
Page 15 and 16: and which elements of the product c
Page 17 and 18: determining the facility area relat
Page 19 and 20: System Boundaries Ideally an LCA in
Page 21 and 22: Most of these data were obtained fr
Page 23 and 24: Chapter 4 - Inventory Analysis This
Page 25 and 26: Figure 4-2: PureCell subsystem and
Page 27 and 28: Air valve subassembly The air valve
Page 29 and 30: water and can be recovered in order
Page 31 and 32: Power data for 2005 value, which wa
Page 33 and 34: Enclosure The enclosure shelters th
Page 35 and 36: • The ‘PET ETH U, adapted to US
Page 37 and 38: Power Conditioning System (PCS) The
Page 39 and 40: Steam ejector The steam ejector is
Page 41 and 42: Steel scrap The scrap rate that was
Page 43 and 44: Use Phase In SimaPro, the use phase
Page 45 and 46: The specific gravity of natural gas
Page 47 and 48: End-of-Life Phase For every PureCel
Page 49 and 50: Chapter 5 - Impact Assessment and I
Page 51 and 52: indicator 99 uses European normaliz
Page 53 and 54: In Figures 5-3 and 5-4 a more direc
Page 55 and 56: Due to the extremely high contribut
Page 57 and 58:
Figure 5-9: PureCell System manufac
Page 59 and 60:
From Figure 5-10 it becomes clear t
Page 61 and 62:
Figure 5-14: PureCell system CSA, w
Page 63 and 64:
esponsible for 72% of the CSA total
Page 65 and 66:
It is obvious that the attention no
Page 67 and 68:
Figure 5-22 shows the impact per ma
Page 69 and 70:
Table 5-3 shows the manufacturing p
Page 71 and 72:
perturbation is also evaluated by l
Page 73 and 74:
are the main opportunities for redu
Page 75 and 76:
A 3% decrease in the platinum recyc
Page 77 and 78:
Material Waste treatment Percentage
Page 79 and 80:
(or at least achieve the assumed 98
Page 81 and 82:
Figure 6-1: Wind/electrolysis syste
Page 83 and 84:
subassemblies that make up the fuel
Page 85 and 86:
For the 100 miles scenario, this th
Page 87 and 88:
Resp. organics 1.41E+03 1.23E+02 8.
Page 89 and 90:
1000 Miles Transport Scenario Figur
Page 91 and 92:
ILS and steam ejector subassemblies
Page 93 and 94:
PCS waste scenario 1 kg Separated w
Page 95 and 96:
The 98% recycling of ILS platinum a
Page 97 and 98:
Table 6-14 shows a comparison of ag
Page 100 and 101:
The goal of this part of the resear
Page 102 and 103:
References 1. Energy Information Ad
Page 104 and 105:
Appendices 101
Page 106 and 107:
Cold transforming steel PureCell sy
Page 108 and 109:
Table 0-4: PureCell system maintena
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NH4+ 0.043917 g NH3 (as N) 0.04 g C
Page 112 and 113:
Stainless Steel 316 2B IISI [8] Pro
Page 114 and 115:
Electric Components PureCell system
Page 116 and 117:
dioxin (TEQ) 9.99E-12 g ethane 0.03
Page 118 and 119:
Mg 10.4668 g Mn 5.42E-05 g Hg 0.001
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adioactive substance to water 1.82E
Page 122 and 123:
Silicon wafer PureCell system [17]
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particulates (unspecified) 17.5 lb
Page 126 and 127:
Appendix E: PureCell System Life Cy
Page 128 and 129:
Appendix G: Calculations for the Pu
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A Life Cycle Assessment of the PureCell Stationary Fuel Cell System ...

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