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Physical life cycle assessment provides the possibility to determine the optimization potential of the manufacturing process, such as reducing energy use, thereby avoiding carbon dioxide and other greenhouse gases. This report describes the physical life cycle assessment of recycled zinc scrap with the purpose of producing zinc alloys for zinc die casting.
Product life cycle assessment (LCA) is usually carried out in accordance with the 14000 series of standards. Similarly, in some areas, general data on raw materials and energy are often used for this purpose. Accurate, product-specific assessments can only be made using simulated balance sheets based on manufacturing processes. This type of balance, also known as physical life cycle assessment, provides the possibility to determine the optimization potential of the manufacturing process, such as reducing energy use, thereby avoiding carbon dioxide and other greenhouse gases. This report describes the physical life cycle assessment of recycled zinc scrap, with the purpose of producing zinc alloys for zinc die casting. The physical data from the digital twin of the zinc recycling or remelting plant and the mapping of the zinc die-casting process provide information about the carbon dioxide emissions in the supply chain from recycled raw materials to finished castings.
The prudent use of resources and the sustainable implementation of circular economy are the starting point for sustainable products. Many terms such as ecological design, cradle to cradle, and efforts to reuse products and materials determine the current debate on sustainable climate protection. Each of these terms takes into account the amount and type of energy used in the manufacturing process, use process, and material recovery process of the product supply chain. The focus is on materials that are suitable for processing into products that use very little energy to get the most benefit, and are also suitable for reuse after proper or long-term use-and once again have a good energy balance.
Zinc material makes this possible-it can be used in a variety of ways, and has appropriate material properties, and can be used for technologies in automotive/mobile, electrical engineering, steel and infrastructure construction, construction, medical technology, pharmaceuticals, etc. Products, health, food, household, etc. -Zinc is used because it is highly likely to be decomposed and recycled. Zinc is "used" rather than "consumed".
In order to achieve these goals, various considerations are required. In addition to the key data on the recycling rate of materials and the content of recyclables in products, life cycle assessment is a tool to illustrate the environmental impact of products. In the future, life cycle assessment will become an increasingly important decision-making basis for investors, purchasers, project decision makers, etc., in order to select materials for specific components, products, factories and other major projects.
In order to optimize the design of supply chains and production processes, simulation tools must be used to strictly map these supply chains to generate physically-based environmental data.
Use simulation-based physical life cycle assessment methods to demonstrate the environmental impact of zinc alloys in the supply chain of zinc die castings. Among other things, it can also display the differences in environmental impacts of SHG-based zinc alloys. Fine zinc (extra high grade/primary zinc) Compared with secondary zinc (recycled zinc), it has a definite recovery ratio. In order to optimize the supply chain and production process, simulation tools must be used to strictly map these supply chains to generate physically-based environmental data. The environmental balance is created by the simulation program HSC-SIM, which is different from the life cycle assessment according to EN 14040 or the environmental product declaration (EPD) according to EN 15804. Surface treatment/passivation of die castings. To this end, the simulation program maps the "digital twin" of the process with specific energy consumption data and the resulting greenhouse gas (GHG) emissions. [Figure 1, 4-7] This method has been successfully applied to various processes of metal production in different industries in the circular economy field [2-5]. If needed, the data obtained can be used to generate the product EPD. The results provide information about the carbon dioxide footprint (GWP) and other environmental impacts (EP, AP, POCP, see Table 1) of primary and secondary materials. This research was carried out by Initiative ZINK with the support of Professor Dr. Dr. hc mult. Markus A. Reuter, TU Bergakademie Freiberg, and REAZN SA, Luxembourg and Adolf Föhl GmbH + Co KG, Rudersberg.
Life Cycle Assessment (LCA) has become an important tool for ecologically-oriented product planning and design in recent decades, and will play an important role in future material and product evaluation. As a science-based tool, it can conduct a comprehensive assessment to optimize environmental impact. The basic characteristics of LCA include consideration of environmental impact, extending from the perspective of the entire life cycle, from the extraction of raw materials to the preparation of their disposal or material reuse. In LCA, all relevant environmental impacts are taken into account, as long as they are quantifiable. The preparation of life cycle assessment is usually carried out in several steps, and the ISO 14040 system has become an internationally recognized standard. 1)
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In this study, a simulation method was used for LCA, [1-5], which allows process-based environmental impact consideration. Metal recycling occupies a key position in ensuring resources for future maintenance and expansion of technology and infrastructure. Regarding the use of secondary raw materials for zinc die-casting, there has been no life cycle assessment study so far. The simulation method and software HSC-SIM2) used, version 10.2, can calculate the impact categories of zinc alloy material production and subsequent processing in the die-casting process in real time according to specific production conditions, rather than general data.
The advantage of this analog method is that the data can be updated at any time with the support of the digital twin of the production process. This means that the performance of the production process and the improvement or deterioration of the environmental impact can be displayed virtually at the touch of a button. In addition, simulations can be used to calculate variants/scenarios, for example, to examine the impact of process changes or the implementation of innovation and production investment on the environment (impact categories, greenhouse gas emissions). This type of environmental impact accounting is a suitable tool to achieve the goal of reducing carbon dioxide and other impact categories in the process of achieving carbon dioxide neutralization. The concept of "avoid-reduce-compensate" in carbon dioxide neutralization can be followed. The simulation method provides a suitable tool to follow this concept to the details of the manufacturing process, and plan and implement appropriate measures. It also shows at which point in the process the use of renewable energy has the greatest impact on the footprint. However, it also shows the so-called limits of reasonable investment and innovation and the limits of thermodynamics in the circular economy.
Figure 1: Base metal flow chart associated with environmental footprint analysis-HSC-SIM model. (Source: Initiative ZINK/Prof. MA Reuter)
The HSC-SIM software used for simulation-based engineering design, as a digital twin, allows all production steps (Figure 4-7) to be included separately, including energy input and output, and unit-related performance parameters of the production unit t/zinc alloy. In the study, the following production processes are regarded as system boundaries. The calculation performed is partly based on energy minimization without GIBBS.
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Based on the assumption of the energy mix used in the GaBi database, the available LCA data on primary zinc and zinc alloy ZAMAK primary alloys (such as IZA) are used.
The values of the activity parameters mentioned in Figure 4-7 are confidential and hidden in the table of the chart. The output data of the process is shown in the result evaluation (Table 1).
Figure 2: The secondary zinc production process. (Source: Initiative ZINK)
Figure 3: Production process of zinc castings. (Source: Initiative Zink)
Table 1: Comparison of the environmental impact of primary zinc/secondary zinc. (Source: Initiative Zink)
Figure 4: Process and result diagram of Furnace F5, including. The accompanying peripheral flow (range 1 to 3). The effective parameter information given in the figure has been kept secret and hidden. (Source: Initiative ZINK/Prof. MA Reuter)
Figure 5: Process and result diagram of Furnace F2, including. The accompanying peripheral process (Scope 1). The effective parameter information given in the figure has been kept secret and hidden. (Source: Initiative ZINK/Prof. MA Reuter)
Figure 6: Process and result diagram of the smelting furnace DC1 in the production of zinc die-casting, including accompanying peripheral processes (range 1 to 3). The effective parameter information given in the figure has been kept secret and hidden. (Source: Source: Initiative ZINK/Prof. MA Reuter)
Figure 7: Process and result description of zinc die-casting production and surface passivation in nano-coating process (range 1 to 3). (Source: Initiative ZINK/Prof. MA Reuter)
Based on real data related to the environment, the production steps of primary zinc/secondary zinc and zinc die-casting (excluding the possibility of surface passivation) were analyzed, and the environmental impact of the entire supply chain of zinc die-casting products was demonstrated for the first time. The results provide a concrete overview of the interrelationship of energy consumption and show the most effective areas for action in reducing energy consumption. By using HSC-SIM software to simulate changes in the manufacturing process, such as using more energy-efficient equipment or changing the energy mix and the share of renewable or alternative energy, the investment impact of improving the environmental footprint can be illustrated. Simulation allows for direct comparisons between existing production processes and future changes, and also involves the financial impact of the investment on the environment-so the investment can be mapped to an environmental balance sheet or sustainability report based on actual data.
For the zinc die-casting supply chain, the energy intensity of each production stage presents a clear picture. In the current research, the state of the complete production process including the production of upstream raw materials is mapped. Both the main raw material usage of zinc die-casting alloy and the usage of secondary zinc are calculated. Therefore, compared to the use of primary zinc (SHG zinc), the use of 100% secondary zinc in the zinc alloy and its specific production and energy parameters in the REAZN SA plant can reduce the CO2 footprint by up to 97.5%. The HSC-SIM software can be used to further optimize this value in the future. Therefore, the development of environmental balance over a period of time can be effectively used for sustainability reporting and corporate carbon footprint (CCF)-any changes can be version controlled in the software. The digital twin of production helps to further implement Industry 4.0 and digitization, and provides production data for sustainability assessment.
Taking REAZN SA and Adolf Föhl GmbH & Co as examples, with the help of software-supported physical life cycle assessment, the production process of zinc recycling is considered to produce alloys for zinc die-casting reuse. KG gives the actual supply chain View of environmental impact. Processing consumption data taking into account indirect and direct energy consumption (range 1 to range 3) is a unique possibility to determine the potential to avoid energy use, process improvements with ecological balance effects, and a company's actual environmental footprint . Produce products in a process-related way. For zinc die-casting alloys from recycled zinc scrap, the company's related environmental footprint (such as carbon dioxide) has been reduced by 97.5% compared to the main material. This value can be assumed to be the initial value used to further simulate the improvement of the company's related processes. The digital mapping of the production process provides the possibility of mapping process variants and conducting commercial games, such as planned investment in the production process. Based on the multiple recovery of zinc, energy and the resulting greenhouse gases have comprehensive production-specific savings potential. In addition, zinc waste is often used as a high-quality recycled raw material in the processing process, which is an overall balance with respect to the environmental impact of extracting zinc from ore.
This research was commissioned by Initiative ZINK and prepared by Professor Markus Reuter; Professor TU Bergakademie Freiberg, based on specific real data from Luxembourg REAZN SA and Adolf Föhl GmbH & Co.KG in Rudersberg. As of June 2020 to March 2021, all data sources have been included in this study. The right to make changes to the presentation is reserved.
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